Mercedes Mullins
Replacing the fuel lines in an E30 is a complex process that requires careful attention to detail. The first step is to remove the old fuel lines from the engine bay, which may involve cutting zip ties or slicing through the old hose with a razor blade. Next, the new fuel lines must be connected to the fuel rail, ensuring that the hose clamps are tightened correctly. The return line must then be run, following the path of the existing hoses. Finally, the fuel lines must be connected to the top of the fuel tank, taking care not to damage the copper pipe.
| Characteristics | Values |
|---|---|
| Connections | 3 hoses: 2 yellow (supply and return lines) and 1 green (runs to the charcoal canister) |
| Upper connections | Supply line (yellow) and return line (green) attached to the pressure regulator |
| Lower connections | Inside of the driver-side frame rail, just in front of the firewall |
| Hose replacement | Unroll a length of fuel hose and run a line from the top connections down to the bottom, following the path of the existing lines |
| Fuel rail connection | Pull the old hose off and slide the end of the new hose over the connection to avoid spilling fuel |
| Hose clamp | Slide the hose clamp over the connection and tighten it, ensuring it's fully over the hard line connection but with a little space before the end of the hose |
| Return line | Run another length of hose down, following the path of the existing hoses |
| Fuel tank replacement | Lift/remove the rear seat and lift the carpet to access the fuel pipes and electrical connections |
| Fuel lines | Separate the fuel lines and mark them if needed for easier identification when reassembling |
| Clips | Use plastic tie wraps or jubilee clips to hold the plastic fuel lines |
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What You'll Learn
Removing old fuel lines
The lower two hoses (yellow) are the supply and return lines. The line above them (green) runs to the charcoal canister. You will need to replace all three. The supply line (yellow) and the return line (green) are attached to the pressure regulator.
If the clips on the original tank are dodgy or in need of replacement, you can use plastic tie wraps to hold the plastic lines. Just don’t tighten them too tight.
You will also need to lift/remove the rear seat and lift the carpet to reveal either one or two access panels. Beneath these, you will find fuel pipes and electrical connections. Undo the wiring plugs (possibly one in each hole if it's a two-hole tank). These are for the fuel pump and the fuel senders (there is one on each side of the two-hole version). A small flat-head screwdriver should split the clips that hold the fuel lines. It's best to replace these with new jubilee clips as they are much easier to do up.
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Replacing the supply and return lines
To replace the supply and return lines of an E30, you will need to pull the old supply and return lines out of the engine bay, from the top. You may need to snip a zip tie or two, depending on how the old lines are retained in the engine bay. Repeat steps 8-16 for the return line.
The lower two hoses (yellow) are the supply and return lines. The line above them (green) runs to the charcoal canister. You will need to replace all three. Start at the top and unroll your length of fuel hose, running a line from the top connections down to the bottom, following the path of the existing lines.
Pull the old hose off of the fuel rail connection. If it’s really stuck, you can slice it with a razor blade. Quickly slide the end of the new hose over the connection to avoid spilling more fuel. Slide the hose clamp over the connection and tighten it. You want the clamp fully over the hard line connection, but with a little space before the end of the hose. Now you’ll need to run the return line. Run another length of hose down, following the path of the existing hoses as before.
If you are replacing the fuel tank, you will need to lift/remove the rear seat and lift the carpet to reveal either one or two access panels. Beneath these, you will find fuel pipes and electrical connections. Undo the wiring plugs and separate the fuel lines, marking them if it makes it easier for you to identify which pipe goes where when you come to put it back together.
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Replacing the line to the charcoal canister
To replace the line to the charcoal canister, you will need to remove the old supply and return lines from the engine bay. You may need to cut a zip tie or two, depending on how the old lines are retained. Once the old lines are removed, you can replace them with new lines.
The charcoal canister is connected to the green line, which is one of the three hoses you will be replacing. The lower two hoses are the supply and return lines, and the line above them runs to the charcoal canister.
To replace the lines, start by unrolling your length of fuel hose and running a line from the top connections down to the bottom, following the path of the existing lines. Make sure to slide the hose clamp over the connection and tighten it, leaving a little space before the end of the hose.
If you are replacing the fuel tank, you will also need to transfer the plastic fuel lines to the new tank. Be careful not to damage the copper pipe. You can use plastic tie raps to hold the plastic lines, but don't tighten them too tight.
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Running the return line
To begin running the return line, you'll need to pull the old supply and return lines out of the engine bay from the top. You may need to cut a zip tie or two, depending on how the old lines are secured. Once the old lines are removed, you can start running the new return line.
Unroll a length of fuel hose and run it from the top connections down to the bottom, following the path of the existing lines. Make sure to use the correct type of hose for the return line, as it may be a different colour or type than the supply line. The return line is typically green, while the supply line is yellow.
As you run the new return line, ensure that it follows the same path as the old lines. This will help ensure that the new line is installed correctly and doesn't interfere with any other components in the engine bay.
If you encounter any difficulties or if the old lines are stuck, you can use a razor blade to slice through them. Be careful not to damage any surrounding components and quickly slide the end of the new hose over the connection to avoid spilling fuel. Secure the new hose with a hose clamp, making sure it's fully over the hard line connection but leaving a little space before the end of the hose.
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Connecting the fuel lines
To connect the fuel lines, you will need to pull the old supply and return lines out of the engine bay, from the top. You may need to snip a zip tie or two, depending on how the old lines are retained in the engine bay.
The lower connections for the three hoses you are replacing are on the inside of the driver-side frame rail, just in front of the firewall. The lower two hoses (yellow) are the supply and return lines. The line above them (green) runs to the charcoal canister. You will be replacing all three.
The upper connections are the supply line (yellow) and the return line (green) attached to the pressure regulator. Start at the top and unroll your length of fuel hose. Run a line from the top connections down to the bottom, following the path of the existing lines.
Pull the old hose off the fuel rail connection. If it is really stuck, you can slice it with a razor blade. Quickly slide the end of the new hose over the connection to avoid spilling more fuel. Slide the hose clamp over the connection and tighten it. You want the clamp fully over the hard line connection, but with a little space before the end of the hose. Now, run the return line. Run another length of hose down, following the path of the existing hoses as before.
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Frequently asked questions
You will need to pull the old supply and return lines out of the engine bay, from the top. You may need to snip a zip tie or two, depending on how the old lines are retained in the engine bay. Then, replace the line to the charcoal canister.
First, lift or remove the rear seat and lift the carpet to reveal one or two access panels. Unscrew these to reveal the fuel pipes and electrical connections. Undo the wiring plugs and separate the fuel lines.
Their connections to the hard lines are on the inside of the driver-side frame rail, just in front of the firewall. The lower two hoses (yellow) are the supply and return lines. The line above them (green) runs to the charcoal canister.
