After successfully replacing the fuel filter on my wife's car without breaking the line to the main pump, and successfully reusing an old washer (because one of the ones included was smashed), I still had a leak at the back of the filter. After trying three times to get the washers to not leak I noticed what the actual problem was- a pinhole in the banjo fitting. Great. Now what?

This is the line that goes all the way to the fuel rail, iirc. Can just the metal fitting be replaced (and where can I get it?) or do I have to tackle the whole line (and where do I get *that*?).

thanks

Thanks for all the responses. I was impatient this morning and tried the dealer. I had read in various places that the line was nla, but according to the local parts department that is incorrect! I ordered the whole line from the dealer for $72 plus tax. HOPEFULLY it will really come in tomorrow.

I feel silly getting new dealer parts for a car with 305k miles on it, but for fuel I think it is probably worth it. My cobbled together fixes usually work perfectly... until there is 12in or fresh snow on the ground and I have to drive 2hrs into NYC or Boston the next day for work. I figure I'll do this one right if the part is really available.

Should I expect any problems or annoyances replacing that line?

I NOTE THAT IPD SHOW A PICTURE OF A BANJO TYPE FUEL LINE FITTING IN THEIR ON LINE CATALOGUE AS OF THIS WEEK. SAYS IT IS A COMMON REPLACEMENT ITEM. I DON'T KNOW IF IT IS YOUR TYPE LINE BUT IT IS VOLVO, AND FUEL, AND BANJO, SO YOU MIGHT WISH TO CHECK IT OUT.

BMWJOHN IN AVON / INDIANAPOLIS

Erik:

Been there done that! Common problem in the salt ladden NE in winter.

While some say to patch it, I like the comfort of doing it right and replacing the line with banjo fitting from the fuel filter to the fuel rail.

I had to do mine on a '91 245 a few years past. The same pin hole leak!!

Not a hard job just a PITA on your back. The part can be obtained from Volvo.

Try Tasca or other on line Volvo parts suppliers that discount. I recall that the part lists for ~$112 but is around $65 or so after discount.

There is a thread here in which the part numbers were noted. I would search the BB for 200 fuel line replacment and find the thread. If I recall Art Benstein left the part numbers.

You may want to try FCP Groton down the road from you sa they may carry stock.

While at it I would alos replace the connector fuel line with banjo's from the main fuel pump to the fuel filter as you do not want to fix one end and then have to go back in a few months to do the other if it too develops the corrosion pin hole leak. The connector Volvo part (only Volvo) is about $30.

While some opt to save a few bucks and patch the line with FI hose and double clamps on each end of the patch line, I personally opt to do it right when it comes to the potential of fuel leakage so it will not happen again.

Good luck.

Al

I have a collection of odds and end fuel lines/banjo fittings--might have the correct size banjo--but not the entire filter to fuel rail line. Fuel hose made for FI (high psi capacity) can be used to bridge between the fitting and the fuel line (I'd use double clamps at the fuel line end since there won't be a barbed end). This can make a temporary/permanent fix. You can have a fitting for the price of the postage. If you're interested -- measure the diameter of the banjo--find my contact info in my profile. -- Dave

Thanks for the offer, Dave! I may very well take you up on it. For the moment though, I have cleaned up and am about to go to dinner with the wife, so I can't do any measuring.

How would I be able to attach the fuel hose to the Volvo fuel line? I know you said double clamps, but it isn't really a hard line - it is more of a vinyl. It doesn't seem like clamping would work.

While replacing the entire line would be the proper fix--patching will work. I've repaired a few that way and never had a failure. I leave the vinyl on the banjo-cutting it flush with the end of the fitting--the fuel hose will fit tight and the barbs will secure it--that end only requires one clamp. At the other end I slip the hose over the line about 6 inches and install two clamps. I use aircraft style clamps (without the screw slits). They put even pressure on the connection and do not crush the vinyl. -- Dave

This was on my '93 940 temporarily.

I did replace it with the real (expensive) OE line, but I do believe it would have lasted a long time — with annual hose clamp inspections.


--
Bruce Young, '93 940-NA (current), 240s (one V8), 140s, 122s, since '63.

Good call on the best hose clamps for the job, BTW. I HATE the classic "cheese grater" clamps, especially around high pressure fuel, for goodness sakes.