I just finished doing an overhaul of the cooling system on my recently acquired 96 E300D, including a new water pump and thermostat. After starting the car I noticed massive drippage, and I was like oh crap it better not be the new water pump, but in fact it was fuel that was dripping, almost pouring. Clearly it's just a coincidence because I didn't touch anything near the source of the leak. Attached is a picture taken from underneath the engine. You're basically looking at the IP from the bottom, above it is the intake manifold, and the arrow points to the source of the leak. Is that the fuel prefilter? The reason I ask is that it looks quite different from the one in the parts database. If not, does anyone know what it is? I verified that it's indeed the source of the leak, and not something above it.

A couple other questions, where does one buy those clear fuel lines? I don't see them listed in the parts database. And does anyone know what the "fuel line seal" is? There's no picture of it.

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2004 VW Jetta TDI (manual)

Past MB's: '96 E300D, '83 240D, '82 300D, '87 300D, '87 420SEL

See this great post by Rick Wiley- 99 e300td injector pump leak

About halfway down the first page, he lists all the part numbers you need. I'd probably start by cleaning things up and replacing those hoses and see what you've got then.

Len

From your photo it looks to me like the leak is from the shutoff switch. It can be the switch itself or the seal between the switch and the IP or the o-ring seals at the fuel line fittings. The fuel prefilter is mounted in the main filter assembly up top and not on the IP itself. As the post above indicated, if the lines are old and brittle you should replace them all. The total cost of the parts is something like $60 and each line comes with new o-rings on both fittings.

Be sure you replace the seal at the shutoff housing too as that was the one area my shop neglected to renew and it leaked after they were done replacing the rest of the fuel lines.

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Marty D.

2013 C300 4Matic
1984 BMW 733i
2013 Lincoln MKz

I had a similar problem with my 93 300D. It does create a hell of a mess.

I initailly thought is was the fuel warmer or some other component.

The leak came from the clear fuel line that is between the IP and engine. I had to tighten it on 3 different occassions for the leak to stop. Twice after I had replaced the manifold and injector line.

U can use a stubby 17mm or a cheap knock off that r shorter than the name brands. Use ur imagination to get leverage because the space is pretty tight.

Check that first.

Thanks for the advice. It's the fuel shutoff valve then that is leaking. The leak is coming from the rear of the valve and not from one of the plastic lines. It seems like the plastic just gave up, like a dam that breaks and lets water gush out. If it was a rubber o-ring I'd think the leak would be more gradual. Now I have to decide whether to just try to replace this fuel shutoff valve or take off the manifold and do a complete overhaul of all the fuel connections. Is there any danger of getting a runaway engine after replacing this fuel shutoff valve? On the older models that seemed to be a problem.

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2004 VW Jetta TDI (manual)

Past MB's: '96 E300D, '83 240D, '82 300D, '87 300D, '87 420SEL

I'd replace all the hoses. You see, the shop that I bought it from put in the new shutoff valve without a new O-ring. Well, of course it leaked like hell. They put in the new shutoff valve a new O-ring and it was better. However at this time they disturbed all the fuel lines going to and from the valve and all that leaked too. IMO, id replace all the plastic lines and the fuel filter you have there.

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01 Ford Excursion Powerstroke
99 E300 Turbodiesel
91 Vette with 383 motor
05 Polaris Sportsman 800 EFI
06 Polaris Sportsman 500 EFI
03 SeaDoo GTX SC Red
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04 Tailgator 21 ft Toy Hauler
11 Harley Davidson 883 SuperLow