New fuel tank nightmare - Mercedes-Benz Forum
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post #1 of 50 (permalink) Old 04-07-2019, 05:03 PM Thread Starter
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New fuel tank nightmare

Today was the day I decided to install the new tank. I've had the old tank in and out of the car a dozen times so no big deal, right? Wrong!!!

I've just about had it with shit parts distributors. I could not get this tank to go in no matter how I tried... so I put the old tank back in... it slipped right in no problem. So I lined the two tanks up side by side to see if I could find a difference. They matched up pretty good until I got to the return tube. The following two pictures tell the story.

Here is the old tank. The red arrow points in the direction the return nipple leaves the tank.

New fuel tank nightmare-merctankreturnnippleold-copy.jpg


Here is the new tank. The red arrow points in the direction the return nipple leaves the tank.

New fuel tank nightmare-merctankreturnnipplenew-copy.jpg

The return nipple on the new tank is so far off that it didn't even come close to lining up with the hole in the bottom sheet metal it must pass through. I thought (for a second of insanity) of trying to bend the nipple but quickly discounted that option because it was sure to snap off if I tried to bend it that far. So the only other thing to do when you can't make the nipple line up with the hole... you make the hole line up with the nipple. (I can just imagine what a field day Nobby will have with that one).

I elongated the hole with my trusty Dremel.

New fuel tank nightmare-mercnewtank4.jpg

Turns out even the elongated hole wasn't big enough so I removed the tank again and made the hole even larger. That worked and I was able to mount the tank and bolt it down but when I went to attach the return line hose to the nipple, there wasn't enough room to get the clamp on far enough to get over the barb in the nipple and the hose would just slide right off. So once again I took the tank out and this time I made the hole big enough for not just the hose but the clamp as well. That finally resolved the return line issue but only brought up the next issue... connecting the external filter to replace the in-tank screen that the new tank can't accommodate. After several failures I decided to abandon the in-line filter idea and just go with the direct feed to the damper cage and rely on the existing fuel filter to do the entire job.

I finished up the rest of the assembly, poured the gas I had removed from the old tank into the new tank and started the engine. It cranked for maybe 2 seconds and fire right off. I backed out of the garage and let the engine run for a minute or two before shutting it down. Just as a precaution I looked under the car to see if there were any leaks... that's when I notice the leak. Damn. I stuck a bucket under the leak and decided I had enough frustration for one day. I'll find the leak tomorrow.

Nobody gets out of this life alive.
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post #2 of 50 (permalink) Old 04-07-2019, 05:56 PM
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(I can just imagine what a field day Nobby will have with that one).
I've matured.
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Don’t’ ever wrestle with a pig. You’ll both get dirty, but the pig will enjoy it.
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Soldier on Old Chap. The Pig is you and you are the Pig.




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post #3 of 50 (permalink) Old 04-07-2019, 05:58 PM
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when you can't make the nipple line up with the hole... you make the hole line up with the nipple.
Anyways, you're doing it wrong.

Maybe you should give this a read.

https://www.goodreads.com/book/show/732026.Sex_101

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Don’t’ ever wrestle with a pig. You’ll both get dirty, but the pig will enjoy it.
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post #4 of 50 (permalink) Old 04-07-2019, 06:01 PM
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That's the problem with aftermarket crap, the time and frustration of having to "adapt" an already inferior product. I'd be hitting the scrapyards to get genuine if oem new is out of the question $$ wise. I've had to use the tank sealer stuff before and it does work, just follow directions to a T.
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post #5 of 50 (permalink) Old 04-07-2019, 06:24 PM
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That's the problem with aftermarket crap, the time and frustration of having to "adapt" an already inferior product. I'd be hitting the scrapyards to get genuine if oem new is out of the question $$ wise. I've had to use the tank sealer stuff before and it does work, just follow directions to a T.
Hehe, you should his 50 page adventure trying to do just that.

The fuel tank is really Jyuma's achille's heel.

At this point, a crappy aftermarket approximation was really the best outcome given the BS he's put up with.

I'm glad you were able to hack it all together Jyuma!

(and for Nobby to discover that his maturity age is older than 12 )
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post #6 of 50 (permalink) Old 04-07-2019, 06:33 PM
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I've matured.
Since when???
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post #7 of 50 (permalink) Old 04-07-2019, 06:47 PM
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Since when???
Maybe a side effect of the anti fart meds that SWMBO insists he take?
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post #8 of 50 (permalink) Old 04-07-2019, 07:42 PM
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I'll have to do my homework and thumb through that thread. I feel his pain for sure.
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post #9 of 50 (permalink) Old 04-08-2019, 03:54 AM
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Shoot Jyuma, talking about bad luck! Having read your other adventures around fuel tank I certainly feel your pain buddy - you will get there!

I can also see why electric cars would appeal to you, maybe consider converting the ol' girl to an all electric? ;-)
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post #10 of 50 (permalink) Old 04-08-2019, 08:09 AM Thread Starter
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Just when you think you've seen everything... this happens;

New fuel tank nightmare-mercfuellineleak-copy.jpg

No, your eyes aren't playing tricks on you... the common wire going to the fuel pump (god I hope it's the common wire) wore a hole in the brand new chrome plated fuel line.

The arrow coming from the left points to the leak in the fuel line. The arrow coming from right points to the wire I pulled away from the fuel line while searching for the leak.

You can't make this stuff up.

Nobody gets out of this life alive.
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