Broken Fuel Line Connector at Fuel Pump

mtfrith · Post by **mtfrith** » 20 May 2010, 05:48

I did what everyone said, "Don't do!" - broke off one of the fuel line connectors at the Fuel Pump on my '96 850 GLT. I saw a couple of posts from a while ago that seem similar, and aggravation in trying to repair. Have you been in this situation? What are your best recommendations on how to repair? Thanks.

Mark

Post by **charlyW** » 20 May 2010, 11:17

best repair I found when I did the same on my 93 850 N/A was to replace the pipe with new fuel line around 1/8th inch or 3/16th cant remember which it was but it was closest to 3mm I could buy and just clamped it up with screw clips solved everything I found the car ran better that way just don't clamp it up too tight so you crush anything as long as its genuine fuel line up to 8-12bar you'll be fine

PS new fuel line is £80 here in the UK, of course can only be obtained from main dealer due to the wierd clamps it comes with the fix cost me less than £5 [$8 ish not sure on the exchange rate now]

1911colt · Post by **1911colt** » 22 May 2010, 22:04

Just took a peak at my fuel pump,in my 2000 V70 wagon, the wife smelt fuel, so I cut the floorboard over the pump,sure enough the line leading to the engine was riddled with tiny holes, right at the 90 degree bend, I cut it off with an oscillating saw, ( No Sparksthat way ) and put on a piece of 3/16 hose with 2 aviation clamps...checked for leaks, none. But the idle on the engine now goes from 850-900 rpm to 1100-1150 rpm...does not stall in gear though, and goes down the road great, does anyone have an idea where to look for the idle problem....or could the pump just have been overworked due to the tiny leaks and needs replacement? Or maybe a sensor? I'm new to a Volvo, but have wrenched on everything from Indians and Harleys to Nuclear Submarines! And am considered a fine mechanic. Any thoughts would be greatly appreciated, Love my wife and don't need her stuck on the side of the road in the wee hours of the morning...works 3rd shift as a nurse.
Pete

TomKlan · Post by **TomKlan** » 19 Jun 2010, 00:16

How on earth you replace this fuel connector? it's not enough room to pull your hand through. Im thinking to get a new one and replace my broken cable (on fuel return)

tomlandy · Post by **tomlandy** » 19 Jun 2010, 10:42

Just went through this...not very fun. (But not too tough.)
You can not simply replace the quick release connector at the fuel pump. The fuel line is shrunk wrapped on the connector, and you can't buy the connector separately. There is a method to replacing the line with parts/line from the local auto parts store, but I chose to order brand new lines from myvolvopartsonline.com.

The part # 9186286. (Line from fuel pump to fuel filter.) Cost from myvolvopartsonline.com was $42.80 USD. ($53.50 USD at dealer.) Wait - that is part # for fuel line DELIVERY. I do not know the part # for the return fuel line. Sorry.

There is nearly ZERO clearance to force/thread the end through the harnessing and up to the fuel pump.
You will need to lower the gas tank to make room.

To get it on, you will need to raise the rear of the vehicle, support it on jack stands and lower the gas tank. This is really quite easy as there are only 3 bolts that connect the tank - just be careful in lowering it down. You will need to also go into the trunk, open the hatch for the fuel pump, and release the lines / disconnect the wiring so that when you lower the tank, you don't break anything. There is a great tutorial on this procedure, but I can't find the URL for some reason.

The process goes:
1. Open trunk, remove passenger side trunk lining & spare tire cover
2. Open fuel pump hatch
3. Disconnect electrical components from fuel pump
4. Lower Gas Tank (Raise Rear of vehicle, support on jack stands, place floor jack under tank for support, remove the 3 bolts, and slowly lower the tank.) Also don't forget to take out the metal O-ring that secures the rubber at the gas cap.
5. Route line through, raise tank and secure.

I hope that helps!

tomlandy · Post by **tomlandy** » 19 Jun 2010, 10:54

Instructions on lowering tank can be found here:

https://www.matthewsvolvosite.com/forums ... =1&t=23851

TomKlan · Post by **TomKlan** » 07 Jul 2010, 06:47

Thank you so much for your help!

I've done it now

thanks again,, for helping me out.

Best Regards

loveMy850 · Post by **loveMy850** » 31 Oct 2016, 11:52

I dont know how bad this is I need to know when removing feul hose from module up inside the connect coupler where the green o-rings set there is red plastic,its right at the beginning od the coupler , a small piece of that red plastic broke, am I in trouble? Ive put in a few orders at ipd for fuelhose at feul pressure regulator,im having vaccumn leaks every where, been sitting a long time,am I in trouble over this tiny piece of red plastic break,as long as my green o-rings are in properly! kinda worried,may sound trival, but............

loveMy850 · Post by **loveMy850** » 31 Oct 2016, 13:15

the red plastic piece,just a small chip broke off is part of the quick connector that keeps the o-rings and hose to the feul pump in place.do I have to replace the hose ,I havent noticed it leaking around the pump!!! Help will some tell me what that red plastic inside the connector between the green oring is,it is not between the o-rings it is at the top of the connector,I lost the piece of plastic, whats my fix?

Post by **cn90** » 31 Oct 2016, 18:10

This is fuel line, so you need to take it seriously.
It is a safety/fire hazard issue.

I made a diagram of the cross-section so you can see how it comes together. The GREEN O-ring is what accomplishes the seal.
The RED plastic is there to hold it in place:

You have 3 options:

1. Dealer fuel line: it is expensive!

2. Get a used line from junkyard (inspect it first to be sure it is OK).

3. Search forum, someone made a ghetto fix using 90-degree barb fitting + generic fuel hose + clamps. I can't find it now, but will post if I find it.