Fuel filter connection fittings

goldxc70 · Post by **goldxc70** » 05 Jul 2024, 19:52

Bust one of these connectors today when changing my fuel filter. It was really stuck on there and just wouldn't let go. I managed to put it back together and hold it in place with zip ties. It's not a pretty job but, so far, no leaks or stalling.

So, I'm guessing the easy repair is to buy a fuel line and put that in? Alternative would be to heat existing line, remove remains of fitting and add a new one?

Has anyone done either of these jobs? My car is a 2004 XC70. The fitting that broke is the engine side of the fuel filter.

Post by **cn90** » 06 Jul 2024, 10:15

This topic has been discussed many times here.

Some useful info is in this thread...

viewtopic.php?t=99985

goldxc70 · Post by **goldxc70** » 06 Jul 2024, 12:13

Yes, I did a search before posting. Here's what either I missed or nobody posted after posting their problems:

1. Where did they get replacement connector?
2. What is correct name/size for connector?
3. What is Volvo part numbers for replacement lines?

My "best" info so far is that the correct fitting on the engine side of the fuel filter is ID6-7.89-M. Also, Volvo don't sell this seperately from fuel lines.

I found this helpful:

Post by **cn90** » 06 Jul 2024, 21:53

I thought "paul1149" mentioned all the parts in the thread linked above?

Post by **scot850** » 08 Jul 2024, 07:59

Paul listed what he used near the bottom of page #2 on the link cn90 posted above.

Neil.

Post by **abscate** » 09 Jul 2024, 03:06

I used the Dorman replacement part, which princess auto should have ?

viewtopic.php?f=1&t=77135&p=542851#p542851

goldxc70 · Post by **goldxc70** » 09 Jul 2024, 15:12

Great info there, thanks.

Here's my two cents:

Per FCP, the Volvo recommendation is to replace line rather than repair it. The part number for my '04 XC70 is 30683029 but at over $200 locally, it seems overly expensive.

The fuel line itself is nylon with OD is 5/16", 7.89mm, but it's covered with a protective layer bringing it to 1/2".
I spent some time on Sunday at a local scrapyard and most of the fuel lines were butchered. But I did manage to pick up a good (yet to be finalized) connector with a short piece of line attached. My plan is to cut out the failed connector and piece in the replacement using Dorman #800-191 Nylon Fuel Line Press Fit Union. My understanding is that the fuel pressure is just over 40psi and I was speaking to someone who uses these connectors in non fuel lines and has tested them at over 80psi.

@abscate My filter is Volvo #30620512 and I installed a Hengst #H220WK which is OEM. Both old and new have the retaining flange.

I'll add photos later.

EDIT: had to abandon that plan for now. The bend on the existing line will make it difficult to install the Dorman union in a straight section of line.

Plan 2: cut damaged connector out and then heat line and press on replacement connector. Line will be reduced by 5/8" but that shouldn't be a problem.

The problem.

The temporary fix.

The "new" part.
EDIT:

The fix.

Just need to watch it for a while to make sure there's no issue and then add some protection