Recently, one of the fuel lines on my 1995 G320 sprung a leak, necessitating its replacement. For that matter, necessitating the replacement of ALL of the fuel hoses. As far as I can tell, all lines are original.
(all photos and illustrations in this thread are from Mike C. of the PointedThree forum)
Below is the EPC diagram of the G320 and G36 AMG fuel line system, as provided by Mike C., a friendly & knowledgable Pointed-Three G-wagen owner:
Note that the fuel flows from fuel tank to fuel pump, then to the fuel filter, then to the engine, in that order.
To start off, I ordered from MB four fuel lines:
463 470 00 75 -- feed line that goes from the fuel tank to the fuel pump inlet
463 470 01 75 -- line from outlet of fuel filter to hard line under truck that feeds engine
463 470 02 75 -- second line that goes from fuel pump to fuel filter inlet (banjo fitting on fuel filter end)
463 470 03 75 -- first line that connects directly from fuel pump outlet to fuel filter
What I found is that:
- the 00 75 line is NLA from MB, and will never be available again
- the 01 75 line is currently backordered from MB, with no availability date projected
- the 02 75 and 03 75 lines are available from MB, and I received them
The line that sprung the leak was the line that leads from the fuel filter OUTLET to the hard line that goes under the truck to supply the engine -- 463 470 01 75. This line has an ordinary "screw" fitting on one end, and a curved "U-shaped" metal end that screws onto the fuel filter outlet.
What I found was at the 03 75 hose is exactly the same length as the 01 75 hose, and ships from the factory with the screw fitting already crimped onto one end (see image below) with nothing on the other end.
I removed the leaky 01 75 hose from my G-wagen, and brought both it and the new 03 75 hose to a local company that does fuel and hydraulic hoses. They agreed to either re-use the metal "U-shaped" fitting from my existing 01 75 hose and crimp it onto the new 03 75 hose, or they would create a new U-shaped metal fitting if needed and crimp it on the new hose.
Here are a couple of views of the back-ordered 01 75 hose (with the U-shaped metal fitting) on the truck, mounted to the fuel filter on the right side of the photo. The hose on the left side is the 02 75 hose, which has the banjo fitting on it as mentioned, connecting to the fuel filter inlet.
As part of this project, I aim to replace all of the fuel lines both in the rear of the truck, as well as those underhood. Thus, as part of this project, I will be doing the following:
- re-ordering ANOTHER 03 75 hose, to replace the new one I bought as the donor for the back-ordered 01 75 hose
- replacing the 02 75 hose (with the banjo end) that goes into the fuel filter
- manufacturing or substituting a hose for the 00 75 hose that goes from tank to fuel pump
- replacing another hose under the truck, 463 476 14 26, which is a short hose in the feed line from the fuel filter to the engine feed. Fortunately this hose is still available from MB, though it is also easily substitutable from other car models and chassis
- replacing both the supply and return lines under the hood, which go from the hard lines under the truck to/from the M104 fuel rail & fuel cooler. These hoses are part numbers 463 470 07 75 and 463 4670 10 75 (both return lines), and feed line 463 476 14 26. Also 461 476 02 26, which runs from the fuel return hard line under the truck to the fuel tank
- Replace the fuel filter (which I already have in hand)
Doing some research, it also appears that there is a 280GE (M110, CIS) fuel hose that could potentially substitute for the back-ordered 463 470 01 75 hose. Its metal "U" fitting is more of an "L" shape, but it appears that it could work. I plan to order one of these to see if it will work correctly as a substitute.
All for now -- I'll report more back as I learn it, and will do a fuel hose replacement HOW-TO once that operation commences.