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Kinked my fuel line that goes to rail.

Help, Advice, Owners' Discussion and DIY Tutorials on S40 and V40. In this forum you'll find S40/V40-specific owners asking and answering questions on maintenance, ownership, repairs, tutorials and almost every do-it-yourself thing you can do to save money owning these Volvos.

1996 - 2004 S40
1996 - 2004 V40

ikiller
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ikiller

Kinked my fuel line that goes to rail.

Post by ikiller » Mon Jul 03, 2017 9:59 am

Yesterday while trying to put my my car back together after doing a full PCV and engine seal job, I accidentally bent the fuel line going to the fuel rail/FPR too far and heard a snap and now there is an obvious weak spot in the hose where it kinks when bent. I am afraid I ruined the integrity of this hose and need a fix. The line is part number 30681549, fuel pipe, costs between $120-$170 and a few days turn around.

Is this a nylon hose covered in rubber?
If it is nylon could I use a nylon fuel hose union like this?:
https://www.amazon.com/Dorman-800-012-B ... B000CIV4OG
They come in 5/16 inch and 3/8 inch sizes, would either size work?

I'm going to check the junk yards in my area, but would appreciate any ideas you guys have for a quick fix.

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alschnertz
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Year and Model: 1995 854T
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alschnertz

Re: Kinked my fuel line that goes to rail.

Post by alschnertz » Mon Jul 03, 2017 2:18 pm

What year is the car?
Where specifically is the kink?
'60 PV544, '68 220, '70 145S, '86 745T, '95 854T, '01 S40
'84 Prelude
'06 MPV
'13 Ford Focus SE

ikiller
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ikiller

Re: Kinked my fuel line that goes to rail.

Post by ikiller » Mon Jul 03, 2017 2:26 pm

2001 S40 with B4204T3 engine. I went ahead and bought the 5/16 union since it was the best option. The kink is in the fuel line that comes from a metal line under the car up under the fuse box and goes to the FPR/Fuel Rail. Specifically it is about four inches after the grey insulation layer stops on the tubing. Unfortunately the kink was at a bend in the tubing, I cut the hose at the kink and confirmed there was cracking of the internal plastic line. I put it together with the union (didn't take as much force as I was expecting, I used wD40 as lube) and I put in some hose clamps to keep it there. Not sure if the hose will fit well with a straight part where a bend is supposed to be. Won't know if it worked until I finish putting the car together.

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alschnertz
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alschnertz

Re: Kinked my fuel line that goes to rail.

Post by alschnertz » Mon Jul 03, 2017 7:08 pm

I hope you used something other than basic radiator clamps.
The fuel pressure is about 45psi. Not sure exactly what the parts you used are rated for, but just keep that in mind.
'60 PV544, '68 220, '70 145S, '86 745T, '95 854T, '01 S40
'84 Prelude
'06 MPV
'13 Ford Focus SE

ikiller
Posts: 5
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Location: US
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ikiller

Re: Kinked my fuel line that goes to rail.

Post by ikiller » Mon Jul 03, 2017 9:07 pm

Thanks for the advice. The nylon fuel line is supposed to be used with the barbed unions I bought without any clamps. I just used regular hose clamps over the rubber/nylon lines for extra assurance. I will try the yards tomorrow to find a good replacement. I'll try the repaired one if I can't get one tomorrow while I keep looking for a reasonably priced replacement. It is really hard justifying putting so much into this car since it is not in great shape, but I own it and my time is cheap. Paying a shop to do this work would basically equal what I paid for it.

ikiller
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ikiller

Re: Kinked my fuel line that goes to rail.

Post by ikiller » Wed Jul 05, 2017 9:14 am

Got a junk yard part yesterday.

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alschnertz
Posts: 630
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alschnertz

Re: Kinked my fuel line that goes to rail.

Post by alschnertz » Wed Jul 05, 2017 6:13 pm

Wow, a junkyard was open on the 4th?
'60 PV544, '68 220, '70 145S, '86 745T, '95 854T, '01 S40
'84 Prelude
'06 MPV
'13 Ford Focus SE

ikiller
Posts: 5
Joined: Fri Jul 26, 2013 3:17 pm
Year and Model: 1961 P210
Location: US
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ikiller

Re: Kinked my fuel line that goes to rail.

Post by ikiller » Wed Jul 05, 2017 6:39 pm

Pick n pull, open 364 days a year, online listing of what cars they have in the yard, with arrival date, a photo, and a smart phone app. $2 dollar entrance fee good for all the yards you can drive to in a day. There are three yards they operate within a reasonable distance of me. Fuel line was about four bucks, headlight assembly was $32.

I got there for the morning opening and there were seven guys waiting ahead of me, when I left an hour later the parking lot was full.

blkbeauty
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blkbeauty

Re: Kinked my fuel line that goes to rail.

Post by blkbeauty » Wed Jul 05, 2017 7:17 pm

I got a used rail off Ebay with the nylon hose, worked like a champ. I didn't need the rail, just the short hose with the quick disconnect. I cut my why doing my PCV system, didn't have the tool to disconnected, so I cut it. Replaced with a fuel hose and clamp, didn't work for, always had a leak. Very high pressure from the fuel system made me get the correct parts. Good luck!

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