Fuel line repair

11Bravo · Post by **11Bravo** » 06 Feb 2021, 15:15

Hello. First post. Glad to better. 2006 S60 was leaking fuel. I found the source by accessing through front right wheel well. The metal fuel line has a pinhole. It’s so small it is a mist of fuel until the pressure drops. I’m assuming this is a delivery line. It’s resting on the front axle. I’ve attached a photo. I’m assuming this line connects to the fuel rail. Could this be repaired by cutting out the bad section and splicing rubber gas line with clamps?
Thx Dave

Post by **abscate** » 06 Feb 2021, 19:55

It’s at 52psi pressure , too high for a rubber hose fix. It needs a flare fitting put in or some sealing strategy

Post by **oragex** » 07 Feb 2021, 07:12

That is a fragile area where the line gets crushed against the subframe, especially if the subframe is lowered a little for work.
What I would try is with cold engine- when the engine is warm, the fuel is warm and keeps building pressure even if you release it - release the fuel pressure at the rail - cover the valve so it doesn't spray, then sand all around the pin hole area to make the metal surface rougher, then mix a tiny amount of JB weld, take a tiny tiny bit to block the pin hole (don't get it inside), let it dry a little bit - not completely so it can stick to the next step -then mix another piece of JB weld and cover well the surface and wrap it around the line too, press well. But more important is to secure the line so it no longer touches the subframe at that place

Post by **cn90** » 07 Feb 2021, 15:51

BMW uses rubber hoses all the time for fuel line.
My guess:

1. Find the correct fuel-rated rubber hose and make sure you enlarge the end using appropriate socket, then slide it at least 1 inch to 1.5 inches into the metal pipe. Then double-clamp it.

2. Or find the appropriate metal pipe from Volvo dealer. I don't know the PN but you can look it up at Volvo dealer.

PS: Not sure this ebay Part fits your car, check to be sure.
It is a bargain at $25:
https://www.ebay.com/itm/34D009-Fuel-Su ... 3821958458

11Bravo · Post by **11Bravo** » 09 Feb 2021, 06:22

Thank you all for the advice. The link to eBay does look like the correct fuel line. I’ll need to look at this more to see exactly how/where my line connects to either end. That option is obviously the best fix and the one I’d prefer providing I can remove and replace the line without much hassle.
I did think about the JB weld application and was hoping someone would talk about that method. I may try this first.
I do get the PSI issue and know they make fuel injection rated hose. I think the double clamp is a good idea.
Going back to the replacement part...I assume the one end connects to the fuel rail. The end toward the back of the engine appears easy to access. Can anyone speak if the difficulty removing and replacing this line?
This is my spare car and I’m waiting for the weather to warm up a little before tackling this. It’s not fun lying in the cold gravel at my age.
Thanks again. I love this site.

Post by **oragex** » 09 Feb 2021, 06:36

Good thing asking about difficulty. The one thing I know is the pressure line from the steering pump makes a similar bend under the engine, and it's extremely difficult to remove without lowering the subframe. So you may want to take a close look before starting. I have on my channel the connections at the rail, if you need - link below

11Bravo · Post by **11Bravo** » 09 Feb 2021, 07:19

Thanks. I’ll take a look.

Post by **jonesg** » 09 Feb 2021, 07:31

11Bravo wrote: ↑09 Feb 2021, 06:22 Thank you all for the advice. The link to eBay does look like the correct fuel line. I’ll need to look at this more to see exactly how/where my line connects to either end. That option is obviously the best fix and the one I’d prefer providing I can remove and replace the line without much hassle.
I did think about the JB weld application and was hoping someone would talk about that method. I may try this first.
I do get the PSI issue and know they make fuel injection rated hose. I think the double clamp is a good idea.
Going back to the replacement part...I assume the one end connects to the fuel rail. The end toward the back of the engine appears easy to access. Can anyone speak if the difficulty removing and replacing this line?
This is my spare car and I’m waiting for the weather to warm up a little before tackling this. It’s not fun lying in the cold gravel at my age.
Thanks again. I love this site.

For JB repair you need epoxy putty that is gasoline safe.
I'd just replace it.

11Bravo · Post by **11Bravo** » 09 Feb 2021, 08:20

Replacing is always my #1 goal if it’s not too labor intensive. If I had a lift this type of work would be a breeze. Does anyone know the size of the line should I decide to splice with a pressure rated fuel hose?

Post by **SuperHerman** » 09 Feb 2021, 12:42

Personally I would replace the entire line. That said, assuming you need to move the car a temporary repair would be smart.

A temporary repair that may work is to buy some fuel resistant rubber with the correct inside diameter to correctly surround the fuel line. Split the hose so it can cover the fuel line hole, with some overlap. Position the spit on the opposite side of the hole. Use a screw clamp or properly sized Oetiker clamp and compress it over the hole. You can use zip tiles on the ends of the hose ends or more clamps.

Not an ideal repair, but it should work.