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Broken fuel line connector from pump to filter

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BigSpud
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Broken fuel line connector from pump to filter

Post by BigSpud » Wed Jan 30, 2019 6:34 pm

I have a 2004 XC70. I managed to break the plastic connector going from the pump into the fuel filter. So my question relates to how best to replace the fuel line and/or connector(s). I attempted to "splice" a Ford type connector into the existing fuel line but had much difficulty. It connects to the filter well but I used a brass 3/8 connector and I'm just not happy with how it fits into the existing fuel line. Must I order the fuel line/connectors from Volvo or is it possible to use high pressure fuel line with Ford connectors? Also, how difficult is it to "thread" the new line from the pump to the filter? (I have already removed the seat and have access to the pump.)

cn90
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Re: Broken fuel line connector from pump to filter

Post by cn90 » Wed Jan 30, 2019 6:50 pm

If no leak, leave it alone.

Another option is to use the Ford quick connect. The problem is how to remove the old barb fitting.

Yes, you can replace the entire line from tank to filter but is a bit tricky due to tight space. This was discussed in the P80 (1993-2000 850, S70, V70 forums).

Any photos of your current setup?
2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

BigSpud
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Re: Broken fuel line connector from pump to filter

Post by BigSpud » Wed Jan 30, 2019 7:04 pm

Thanks for quick reply. I can't take photos until Friday. I used a Dorman Ford quick connect nylon repair kit and attached it to the filter. Then I "spliced" that into the existing fuel line via a brass elbow. I used clamps. Getting the brass fitting into the existing fuel line was extremely difficult.

BigSpud
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Re: Broken fuel line connector from pump to filter

Post by BigSpud » Wed Jan 30, 2019 7:21 pm

I see from the posts you referenced the Volvo fuel line might be a 5/16 ID. That might be why the 3/8 didn't want to fit.

BigSpud
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Re: Broken fuel line connector from pump to filter

Post by BigSpud » Fri Feb 01, 2019 11:07 am

I have an update. I found a fitting at a Western States Cat dealer and got a good bite on the fuel line coming from the pump. But now the pump is not working at all. Something I did - for certain. The fuse is okay. So now I'm searching the Matthews site for tips on checking the pump. I suppose this might be the time to replace it since I've already have access to the pump. Then again.... I might wait till spring...

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