Gas leaking from top of new fuel pump. Yikes!

[squiggy]

I was finally able to fix the gas leak from the damaged 90 degree quick-connect fuel line connector that snaps onto the top of the fuel pump. What I ended up doing was going to the salvage yard and cutting a connector off of a wrecked Volvo 850. (And while I was at it found a practically pristine after market OEM fuel pump complete with new, white plastic housing that you see online for around $350 but bought it for only $12 bucks. So now I have a nice spare fuel pump!).

Well... this quick-connector removale and installation was more difficult than it sounds. There is a hard plastic fuel line hidden inside the soft rubber fuel line you see when looking at your fuel pump. And boy is that hard plastic fuel line secure on that connector! The only practical way to remove the connector from the fuel line is to cut the fuel line.

Then I spliced the fuel line on my car (photos soon). That was not fun as the hard plastic fuel line will not securely seal around a connector or brass splitter unless you heat the plastic. Of course you can't heat plastic around a full tank of gas! The only way to do that safely is to submerge the plastic in nearly boiling hot water. Not an easy thing to do in the trunk of your car!! But I figured out a way to do it and will show you in the photos.

Anyway, I obtained a fully functional 850 again on Christmas Eve that does not leak gas. Just in time to do some very last minute shopping for my little nieces and baby nephew!

Merry Christmas!

[squiggy]

I was not 100% happy with my 'spliced' fuel line and in an effort to snug things up a bit damaged my splice and caused another fuel leak. So I gave up and spent an afternoon lying on my back in the mud at the salvage yard to obtain a complete fuel line (from fuel pump to fuel filter). BTW... the fuel line I removed was from a sedan and I have a wagon. The fuel lines are the same length in both cars. To remove the fuel line you must have the car jacked up, remove the passenger side rear wheel, lower the gas tank (only one bolt not hard to find) and unclip two hose 'organizer' straps. On of these straps you will not be able to see or unclip until you lower the fuel tank.

Anyway... NOW I finally have a working 1994 Volvo 850 Turbo wagon again that is not patched together.

[squiggy]

[holler1]

I admire your tenacity in getting this fixed for minimal cost. One thing I noticed in the pictures; I think the small part that was caught in the fitting is actually part of an O-ring that probably was there to seal the fitting at the top of the tank. It looks to me as if the original leak may have been due to the O-ring cracking.

[squiggy]

Thanks! I'm glad to have a fun, safe, & comfortable car back on the road! I think you are right that the green rubber thing is some kind of o-ring, although if so it is a kind of internal sealing device that's common to all of the fuel line quick-connectors.

[pkc303]

Well, we have the same problem. Went to the salvage yard, picked two lines, and will attempt to replace the lines. I don't think ours is caused by the fuel lines, but the gasket around the fuel pump. We bought that at Volvo. The lines would be around $160 to replace. We spent $11 at the junk yard so far. Will let you know how it goes.

[ghoulama]

you need to crank that plastic piece that compresses the seal as much as possible or it will leak.

[loveMy850]

old post ----are your o-rings set properly

[loveMy850]

yes it is the o-ring, I changed my pump years ago, nowhere could I find o-rings had to order them.