Broken Fuel Line Connector at Fuel Pump

loveMy850 · Post by **loveMy850** » 05 Nov 2016, 19:23

I went to the yard,I needed a new feul pump,and module,it looks real good no guarantee that pumps good,I also got the fuel line with the connector,the line had been cut,I dont know if that will do me any good unless I can connect the line to my feul filter somehow ,are there adapters or something like for such a thng?,I know I'm totally with you when messing with feul ,this is why my concern,Im not a mechanic but I try and do wht I can, living on a shoestring at the moment.Thanks for all your replys

loveMy850 · Post by **loveMy850** » 05 Nov 2016, 19:42

Whoops my bad I think I meant feul pump connect line to feul line

loveMy850 · Post by **loveMy850** » 19 Nov 2016, 12:47

ok I found the ghetto fix, can I use this at the pump you think,?, kinda scary, but so is this chip in my connector! oh gosh I dont know,living on a shoestring, to have the tank drooped, probably looking at some cash, can do minor and some mechanics but not the heavy stuff.

loveMy850 · Post by **loveMy850** » 17 Dec 2016, 10:53

Hi c90, I agree just know ing this chip is there is well you know,so can you tell me or pic me on how and where the bolts are to lower the tank, Im thinking of going to the yadr but volvos are very limited where I live Thank you.

Post by **cn90** » 17 Dec 2016, 13:27

Don't worry about "ghetto" fix.
My 1998 BMW 528i fuel hose is attached using standard hose and clamp at the filter area, none of this fancy "quick disconnect" stuff.

I think the Volvo hose Internal Diameter is 8mm (check to be sure).
Go to hardware store and buy a 90-degree Barb fitting with O.D. about 8mm or so (I am guessing barb fitting for I.D. 1/4-inch should have an O.D. = 8mm or so).
Fuel hose: buy in bulk, maybe 3-4 feet, get the good fuel hose with I.D.

Gas tank ---> Short Hose + 90-degree Barb fitting ---> Long Hose all the way to Fuel Filter.
If you are careful, you don't have to drop the gas tank: use the old hose as a guide, attach new hose with tape and pull it through.
Or use a long coat hanger wire to pull it through.

Post by **erikv11** » 17 Dec 2016, 15:30

All the hoses are clamped to the tank in two places, be sure to unhook the clamps. Even with the plastic clamps unhooked I think it would be impossible to pull the old hose through without dropping the tank a bit. There is very little clearance and the factory lines are very stiff, if you try using those without dropping the tank but you will more likely just waste a bunch of time. The coat hanger idea could possibly work, I would give that a try. Or if you have access to a fish tape like is used for home electrical wiring.

When the tank is empty it is lightweight and easy to drop - see the link from earlier in this thread. It's not hard to do but it does help to have a small jack to place under the fuel pump.

PeteB · Post by **PeteB** » 19 Dec 2016, 08:33

https://www.matthewsvolvosite.com/forums ... 26#p425526

novaman83 · Post by **novaman83** » 27 Jun 2017, 09:15

The fuel line numbers are: high pressure fuel filter to pump 9186286 at Eeuroparts $58.99.This is what breaks the most often.
Low pressure return line 9189294 $97.99.
I had a heck of a time getting these part numbers. It took a great parts guy and a tech to figure out the Volvo fuel line diagrams!
I could only find OEM.
Chris Rice is a HERO!
BTW, to prevent damaging the high pressure connector, get a small nail puller and use a Dremal tool to make the opening wide enough to fit around the tube going into the Thanks to the guy who suggested it! That connector is on tight for safety reasons..

Post by **erikv11** » 27 Jun 2017, 09:43

In general for P80 cars there are some variations in the fuel system even within years, so for replacing these lines it usually works to just look up the parts the usual way, then if compare with the pictures to be sure. But, glad you found a parts guy to make it certain for you.

Junkyard is definitely a good source for these lines if you have the tim and patience and want to save several $$$, usually these only need replacing if the connector was damaged by the user, or the line got whacked by some road debris.

djtaylor · Post by **djtaylor** » 10 Dec 2018, 12:28

Well I know the thread is old but still valid info so just to add my pain from the weekend when for the second time I had changed the fuel pump. I did the pump quickly but because it started raining, I rushed trying to get the pipes back on and broke the red plastic clip with the result that fuel was pumped all over the drive.

Like everyone else in the thread, all that's needed is that replacement but the hassle that is the whole pipe seemed to be the option but I had also already ordered a "genuine" pump from Ebay which arrived "not as the picture" which irritated me a bit but it is a Bosch pump and I noticed that the two connectors were still on the top of the pump even though they were cut off. No problem, I didn't need the rest, just the red clip!

I have to say, if you get hold of the connector (easy enough in a scrap yard) and don't want to drop the fuel tank and replace the whole pipe, getting the red clip out is really very easy.

All you have to do is pull off the large boot that slides and then carefully pull the red clip out and finally fish out the old O rings and replace in the pipe that you're going to keep.

Goes without saying that refitting is trivial, pop two O rings back into the fitting, in goes the red clip and push the cover back on.

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Broken Fuel Line Connector at Fuel Pump

Re: Broken Fuel Line Connector at Fuel Pump