Disconnecting fuel line from filter, why does volvo use fuel connectors from hell ? (And how to disconnect them ?)

[shodanx]

title Disconnecting fuel line from filter, why does volvo use fuel connectors from hell ? (And how to disconnect them ?)

Hi,

I have a XC70 03 with leaking rusted fuel filter

Got a new filter, tried to replace it but it didn't work as I'd hoped.

On the fuel line connectors, there are gray tabs that you're presumably supposed to press to release the hose.

I pressed them, the hose turns but it doesn't release. Got in a better position, pushed as hard as I could with my fingers, I cut myself a little, push-pull-twist-yank-push-pull and so on, it just won't let go

I squirted a bunch of penetrant lubrication fluid into the hose connectors






I tried squeezing it with the vice grip, but that doesn't squeeze the tabs, it just holds on to the connector's body



I tried the smaller vice grip but same thing



I tried wrapping zip ties around it and squeezing the heads of the zip ties onto the gray tabs



But the awkward position, trying to juggle the zip ties, the vice grips and everything was just too much !

So I had the idea to put tape around the connector



And then stick the cut heads of the zip ties in place



Now I've got them good on there !



push-pull-twist-yank-push-pull again, but it won't budge, it does turn just fine but it won't come out ! Yes, I tried pushing hard !

The tabs are pushed in permanently now, I wonder if that's going to be an ever bigger problem ?



I went on youtube and the forums, looking for the trick maybe ?

--------------
youtube and forum results here


A video showing you should be able to take it off with just your hands


this video is from an XC90 but it's the same setup


Another video showing just how dam easy it is supposed to be


fcpeuro, showing again that it's super easy


these guys are using some tool


this person has the same problem, pushed on the buttons using open end wrenches
https://volvoforums.com/forum/volvo-850 ... uck-60568/

this person used jumper cable clamps
https://volvoforums.com/forum/volvo-850 ... ump-50495/

this person gave up and brought it to the dealer
https://volvoforums.com/forum/volvo-s40 ... cts-70542/

this person didn't resolve their stuck fuel filter, suggested using a special tool or going to dealer
viewtopic.php?p=627121&hilit=fuel+filter+disconnect

this person did the fix, and then it blew out the lines under pressure, suggest
viewtopic.php?p=599775

This post also mention they are hard lines covered with rubber so you can't just cut them and clamps
viewtopic.php?p=448365

This person cut the line, discovered they are hardlines, they have not been heard from since and are presumed dead
https://www.swedespeed.com/threads/2006 ... ts.656305/

This person says "couldnt be easier"
https://www.swedespeed.com/threads/fuel ... er.354018/

This person's mechanic broke the connectors and replaced with generic screw hose clamps, are worried about leaking gas on the exhaust
They reported putting 1000 miles on the car, they have not been heard from since and are presumed dead
https://www.swedespeed.com/threads/fuel ... xc.218735/

This person broken the fuel filter connector, paid 990$ plus towing to have it fixed by replacing the entire line
https://www.swedespeed.com/threads/fuel ... ost-894536

This person says to squeeze, push then pull
https://www.volvo-forums.com/threads/he ... #post-3281

This person also tried everything in 2009, they have not been heard from since and are presumed dead
https://www.volvo-forums.com/threads/fu ... ost-112439


I see on ebay, there are special pliers that might do it ?







--------------

my friend lended me his dad's hose disconnect tool kit as well as a pep talk



I tried the 1/4" tool



I tried the 5/16" tool



I tried the filter inlet side, that's the leaking side, it broke off immediately





It's not budging, mosquittos are eating me alive and it's 3AM so I'll try again tomorrow


Another day, what we're looking at here





1/4" tool again, it's in the "out" position



1/4" tool, in the "in" position



Trying to have a look inside the connector





Trying the 5/16" tool again

out position



in position



Trying another tool that fits



I can hear clicking sounds, but it's not moving



I tried with the zip tie heads again





It's well squished



And I've got another tool to help me pry the connector from the filter



Well, I'm stuck, I also tried heating the line with a hair dryer, but no effect

I ordered the two fuel line disconnect tools off ebay, I hope they will arrive before the end of next week !

Is there any way to buy replacement hose end connectors, so I could just cut off the lines and push in new connectors ?

I really really really don't want to change the lines, especially not the line that goes to the fuel pump !

I've seen that you have to cut a hole in the floor or drop the subframe to get at the fuel pump so .

[jonesg]

"I've seen that you have to cut a hole in the floor or drop the subframe to get at the fuel pump so ."

No way, xc70 wagon has a fuel pump access hatch under the rear bench seat.
but disconnect battery or you have an srs code to add to the woes.

don't give up yet though, I would use a small pry bar between the connector and the filter body to push it off.
Also try a 90 deg hooked pick to pry the O ring from the rusted pipe.
You'll probably need a new connector at this point anyway so force it off and be damned.

if we never from you again....?

[abscate]

Usually you break the oring to metal binding by rotating the fuel filter until the metal is turning in the oring, but they can be a real b***** to get unglued when they get stuck. The tabs are retracting a lip which catches the flange and holds the filter in, it isn’t affecting the actual sealing at all, that’s done by o rings. Once you dig in there you usually mess the orings up, so new hose is in the works

You can squeeze them **** too much*** you just want the fingers to retract to allow the filter to slide off the flange on the pipe. Slight finger pressure is enough while you tug on the filter. Get the filter out of the bracket so it’s free to move ,rather than hose


Oooof, tough day

New hoses are about $80 for the rear, $100 for the front. You can splice into these hard lines with the Dorman kit and some work ( you have to warm the nylon line, force in a splicer, then clamp

[Blacklab467]

I ended up busting the little grey piece accidentally after going through what you did, lots of soaking with WD40 and such. If memory serves correct I think I was able to harvest another grey retainer at the wrecking yard. I also changed and lubed the o-rings. Hope this helps if you already broke the grey clips.

[CrossCountry]

Just replace the hoses with high pressure fuel injection hose with conventional hose clamps. Done!

[vtl]

Just replace the hoses with high pressure fuel injection hose with conventional hose clamps. Done!

High risk it will eventually come off. Use Oetiker clamps at least.

[Goldchemist]

Wow you really tried to get those off. I ended up prying mine off and pulling the o-rings out, didn't ruin the o-rings though. If I didn't ruin the o-rings and the grey clips, is there a chance I can just put it all back together and clip them on? Anyone ever done this. It would save me from having to replace the lines etc. Thanks!