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Broken fuel line clip to fuel filter

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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Paul_okie
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Broken fuel line clip to fuel filter

Post by Paul_okie » Sun Aug 07, 2016 3:33 pm

2000 V70 XC AWD.
First, after reviewing advice on location of filter I removed 3rd row seat to access the panels in rear. No fuel filter there - it was behind the tank and easily accessed from underneath the car. Doh!
Then, probably because I was in a hurry due to frustration from above, I managed to break the fuel line right at the clip to the fuel filter (tank to filter side). So, the rest of this post describes a hack job to get my car back in business. Very possibly unsafe, and who knows how long this fix will last. Fingers crossed.

After some fiddling and searching at auto parts store I bought a dorman repair kit made for this very problem on American made cars. And I bought a filter that would fit both the Ford style filter clip on the "in" side and was long enough on the "out" side that the 2000 Volvo clip would also work. Later I searched what vehicle the filter is designed for and it's actually a 2001 V70 filter. Perfect. So, spliced the doorman kit to my existing broken "in" fuel line. This is the most difficult part and I wasn't that great at it. So, I put a hose clamp on just in case. The fuel line is 5/16" nylon. You have to trim it off several inches to get past the factory line/clip union. I used a propane torch well away from vehicle to heat the brass barbed splice piece from the repair kit and used pliers to twist and shove it into the old nylon line as far as I could. On the "out" side of the filter I just used the existing Volvo clip. I considered grinding the lip off the filter pipe, but thought I'd try it as is first. So far so good. Have run around quite a bit with no leaks.
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2000 V70 XC 153k (sold)
2001 XC V70 162k

cn90
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Re: Broken fuel line clip to fuel filter

Post by cn90 » Sun Aug 07, 2016 7:47 pm

Nice mod but I'd put some zip tie or run a solid wire (the solid copper wire used in household wiring) all around the filter.
2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

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Paul_okie
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Re: Broken fuel line clip to fuel filter

Post by Paul_okie » Sun Aug 07, 2016 8:09 pm

Oh yeah. I took the pic before I put the bracket back on. The bracket fits perfect. The 2001 filter is same circumference.
2000 V70 XC 153k (sold)
2001 XC V70 162k

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Paul_okie
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Re: Broken fuel line clip to fuel filter

Post by Paul_okie » Sat Aug 20, 2016 5:55 pm

Update. My crappy barbed splice started leaking. Replaced with this.
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2000 V70 XC 153k (sold)
2001 XC V70 162k

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theWIFES_S70
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Re: Broken fuel line clip to fuel filter

Post by theWIFES_S70 » Sat Feb 18, 2017 8:42 pm

Don't mean to be jumping on this thread. But had the same thing happen today to my brother's V70. (I think the boy just doesn't know his strength!) :lol:

This leaked all over the place! Little red pieces of plastic came out of it...
v70_broken_fuel_line_connec.jpg
So we ended up using this fuel line and appropriate fuel line clamps.
v70_fuel_line_connector_fix.jpg
We cut back the rubber housing around the fuel lines and slipped this on. Real snug fit. I looked for little brass fittings to fit inside of the hose but our Autozone didn't have anything like that... Turned the car on for a few minutes checked for leaks, nothing. Then I had my brother drive around for a few minutes. No leaks. I wonder if we should spray it down with rubberized paint to keep it from getting nicked and so on. Has anyone else done something similar to this?
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1998 Volvo S70, N/A, 5-speed, 183K
2007 Volvo S40, 2.4i, 5-speed, 97K

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brunocerous

Re: Broken fuel line clip to fuel filter

Post by brunocerous » Thu Nov 30, 2017 7:23 am

theWIFES_S70 wrote:
Sat Feb 18, 2017 8:42 pm
Don't mean to be jumping on this thread. But had the same thing happen today to my brother's V70. (I think the boy just doesn't know his strength!) :lol:

This leaked all over the place! Little red pieces of plastic came out of it...
v70_broken_fuel_line_connec.jpg

So we ended up using this fuel line and appropriate fuel line clamps.
v70_fuel_line_connector_fix.jpg

We cut back the rubber housing around the fuel lines and slipped this on. Real snug fit. I looked for little brass fittings to fit inside of the hose but our Autozone didn't have anything like that... Turned the car on for a few minutes checked for leaks, nothing. Then I had my brother drive around for a few minutes. No leaks. I wonder if we should spray it down with rubberized paint to keep it from getting nicked and so on. Has anyone else done something similar to this?
IMG_20171130_095258110.jpg
Update: This fix lasted about eight months before I noticed a fuel odor and found that the metal clamps were damp with gasoline and the filter was rusted. I tightened the screws gently, and this worked for about another month. Today, the smell is back.

My brother sent me the link below, but I could've sworn I read about someone fashioning one out of high-pressure copper tubing. Did I dream it?

https://www.tascaparts.com/oem-parts/vo ... pe-9142683
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Last edited by brunocerous on Thu Nov 30, 2017 7:59 am, edited 1 time in total.
2004 XC90 AWD
2000 V70, base, MT, 'The Silver Bullet'
1998 V70, base, AT, 'Blue Steel'
1998 V70 T5, AT, project
1999 V70 XC AWD, AT (RIP)
1998 S70 T5, AT (RIP)

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erikv11
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erikv11

Re: Broken fuel line clip to fuel filter

Post by erikv11 » Thu Nov 30, 2017 7:54 am

Those fuel pipes are super expensive so I have always gone with a parts car or junkyard replacement.

I've replaced the pipe from the filter to the engine on a FWD car, it was pretty easy I did it in the parking lot of my kid's workplace, I did bring the hydraulic jack and jack stands. Pulling the replacement pipe is easy enough that it wouldn't be so bad at the junkyard. Not sure how that would be pulling one from an AWD, I haven't seen the routing. Just be very careful where the pipe connects to the FPR housing at the engine, it is easy to break those plastic nipples.

For the fuel tank side I have also replaced the pipe, again with a parts car item, that would be much more of a hassle on an AWD as it requires dropping the tank.
'95 854 T5-R, Motronic 4.4, 185k
'96 855 NA, 145k
'98 S70 NA, 220k (living out west)
'98 V70, T5 tune-injectors-turbo, LPT engine, 285k
'06 S60 R, 160k
gone: '96 NA 850 210k, '98 NA V70 182k

scot850
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Re: Broken fuel line clip to fuel filter

Post by scot850 » Thu Nov 30, 2017 11:06 am

The AWD one is a nightmare to do without dropping the rear sub-frame and fuel tank as the pipe runs over the top RHS of the tank to the filter. Either pipe would be a nightmare as the one to the tank cannot be accessed at the tank without dropping the front of the tank, and again the pipe runs over the top of the fuel tank. I did a thread on replacing the rear sub-frame on my 2000 'R' AWD a couple of years ago and there are lots of pictures there of the layout. I replaced the pipes on that car due to the age and condition of the originals. The FWD 2000 base was no better as the pipe is so short at the engine side you could easily break it as there is little flex to allow it to be removed.

Good luck to you both.

Neil.
2000 V70 R - still being an endless PITA
2006 XC70
2003 Toyota 4Runner V8 Limited
2015 Kia Sportage EX-L
1993 850 GLT -Sold
1998 V70 XC - Sold
1997 Volvo 850 SE NA - Went to niece in California - Sold
2000 V70 SE NA - New project and test bed - Sold

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erikv11
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erikv11

Re: Broken fuel line clip to fuel filter

Post by erikv11 » Thu Nov 30, 2017 11:49 am

scot850 wrote:
Thu Nov 30, 2017 11:06 am
The AWD one is a nightmare to do ...
This is such a recurring theme, all around the car. Makes me think I will not like keep the S60R into its old age ...
'95 854 T5-R, Motronic 4.4, 185k
'96 855 NA, 145k
'98 S70 NA, 220k (living out west)
'98 V70, T5 tune-injectors-turbo, LPT engine, 285k
'06 S60 R, 160k
gone: '96 NA 850 210k, '98 NA V70 182k

scot850
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Re: Broken fuel line clip to fuel filter

Post by scot850 » Thu Nov 30, 2017 1:05 pm

Hi Erik, can't talk about the workings in too much depth with the P2 AWD as I have't worked on our 06 XC70 much. I leave it to the dealer for the most part. I know replacing the Evap pump is a true swine, involving dropping the rear of the muffler section to access the pump hidden up between the rear floor pan and the spare wheel above the rear axle.

Neil.
2000 V70 R - still being an endless PITA
2006 XC70
2003 Toyota 4Runner V8 Limited
2015 Kia Sportage EX-L
1993 850 GLT -Sold
1998 V70 XC - Sold
1997 Volvo 850 SE NA - Went to niece in California - Sold
2000 V70 SE NA - New project and test bed - Sold

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