https://www.volvopartswebstore.com/products/Volvo/Pressure-hose-no-longer-available--sold-out/1236410/6842618.html
I have 93 945w the rex regina fuel system,,base engine,Its the same setup as my 89 745 & that car did 34mpg & maybe 26 around town.
this similar setup But Ive never been able to get over 22,mpg max!!
Ive replaced almost all parts & mpg has gone up & down for no explantion till finally Jim Bobbit told me this is the part thats the problem..
This car has 1 fuel pump in the tank NOT 2 as the 89 745 had...so when i changed the fuel filter the banjo fitting goes to a nylon line &then to the engine compartment..Ive been told that the nylon line has to be compressed around the bajo fitting,,,
Im trying to figure out how to find another or to rig another solution to fix it??

I got a banjo fitting ,nipple off ebay theyre made by a machinist in N.H.
i took the intake nipple off the fuel line The nylon line is covered by regular fuel line to protect it. took it to a properly aged mechanic Jim Bobbitt In Pburg,& he had the tool to press it onto the new 5/16" nylon line & its uses 2-5/16 "fuel injection pinch clamps & I think it was 2 3/8" clamps,,one on each end..to the banjo fitting. he charged $10,,,then I secured the banjo fitting w new copper seals.ran it to the drivers side of the back of the engine,,,nice ^& tight now& mpg is to 20 which isnt that good,,

I wonder if the banjo bolt & fitting can just be 3 d printed???

Dear blindboy,

Hope you're well. Fuel system parts are mostly "mission-critical": f they fail, the vehicle stops. That's the "least worst" outcome. The "worst" outcome is a fire.

Whatever the cost savings between metal parts ($25, for both parts) and any substitute material, I'll go with the time-proven metal parts.

This is not to say that polymer items cannot be very durable. They can. But the printing of 3-D parts in polymer is in its infancy. We simply don't have enough history to know which polymers will be most durable.

Plastic-frame handguns are about 35 years old. Up to 1985, firearm frames were made of metal (steel, brass, or aluminum). We know that polymers used in handgun frames are indeed very durable. In 1985, I doubt that was clear.

Hope this helps.

Yours faithfully,

Spook

I got the new part ,nw Im wondering how to get the old banjo off to install the new 1...

NLA Volvo 240 Fuel Filter Outlet Banjo Fitting on ebay

https://www.google.com/search?q=hardware+fittings.banjo+fitting&rlz=1C1CHBF_enUS837US837&sxsrf=ALeKk01dUO8QPe3MEAT54bFYkUYNZBcnyA:1603415252946&tbm=isch&source=iu&ictx=1&fir=y49phY_vfkVSoM%252Cd5EBYrNvx54DAM%252C_&vet=1&usg=AI4_-kThfr5mRsMMHKgK0meeHlfuNzcVRw&sa=X&ved=2ahUKEwjn5tCkw8nsAhXLlXIEHZs2DtoQ9QF6BAgGEDQ#imgrc=UssBlfMNShDrQM&imgdii=uM8YQk59-gYV9M


a simple search & I found them,,just need to know the right size??

Dear blindboy,

Hope you're well!! The no-longer-available pressure hose can be replaced with ordinary fuel line, if the fuel line is rated for fuel injection use.

On my '93 940 (Rex-Regina) the hex-head banjo bolt was found to be corrosion pin-holed, while the car was at a shop for state-required inspection. I didn't want to drive with fuel spraying on the under-body. I supplied a new fuel filter, copper crush washers and a banjo bolt.

The mechanic installed same. He has a tool that presses the barbed fitting - through which passes the banjo bolt - into the plastic fuel line. Without that tool this is hard to do as the plastic is not very stretchy (which is a good thing). He ran the new fuel hose up to the fuel injector rail and pressed it on.

Since then, all is well. So, either get the special tool or find a substitute for it.

Hope this helps.

Yours faithfully,

Spook

But what seem to be the problem is the banjo fitting that seems to have a pinhole leak NOT the hose,,

Dear Blindboy,

Hope you're well and stay so! This handful of words: "the problem is the banjo fitting that seems to have a pinhole leak NOT the hose." states precisely the problem.

The banjo bolt (hex head) - #973950 - is available from www.fcpgroton.com. It costs about $9.

The fuel hose with the barbed fitting is "no longer available". That's why I explained how standard plastic fuel-injection-rated hose can be pressed onto the barbed fitting, which the banjo bolt secures to the fuel filter.

BTW, when referring to a parts diagram, that shows several related parts, it is best to explain which of the parts shown is the one that you seek.

Hope this helps.

Yours faithfully,

Spook

The problem is the fitting--not the bolt. It's the fitting that rusts pinhole leaks. Seen it many times and used F.I. rated hose & double clamps on salvaged banjos. - Dave

(from http://cleanflametrap.com/fline.html#fitting )
--
Art Benstein near Baltimore

"I love the smell of gasoline in the morning, afternoon, or evening.
This may explain why I see green and blue elephants sitting on the roof of the house." - Research

I should get the banjos tomorrow,I cant wai to replace them *& then check the MPG...to finally figure it out!!!

iM TRYING TO FIGE HOW TO FORCE THE NYLONG LINE ONTO THE BANJO FITTING...i BOILED IT IN WATER & GOT 1/2 THE WAY ON..BUT NO MORE

Dear Blindboy,

Hope you're well. There are specialized tools to do this job. See: https://www.speedwaymotors.com/shop/hose-installation-tools~14-25-327-13460 . These tools' price makes them affordable only for full-time mechanics.

It is hard to grip the hose with enough force, to push it onto the barbed fitting. So, you might try putting the barbed fitting into boiling water. Metal holds heat better than does plastic tubing.

With a tongs, remove the fitting from the boiling water and - as fast as you can - clamp the fitting in a vise. Then take the hose end from the boiling water and using a rag to protect your fingers, push the hose onto the barbed fitting.

I'm guessing the metal will retain enough heat to keep the hose pliable, until it is fully seated on the fitting.

Hope this helps.

Stay Well!!!

Yours faithfully,

Spook

THANKS JIM BOBBITT...hE HAS THE TOOL,,,$10 !!https://www.cartalk.com/nj/phillipsburg/130102/bobbitts-automotive

Dear Blindboy,

Hope you're well. To what tool do you refer? The link is to a business listing, not to any specific item.

Stay well!

Yours faithfully,

Spook

When did ou last talk to him??I see that was 9 rs ago??

Dear blindboy,

Hope you're well. Here's a link to the parts-maker, to whom Art Benstein kindly drew attention:

https://www.ebay.com/itm/NLA-Volvo-240-Fuel-Filter-Outlet-Banjo-Fitting-NEW/130211483659?h ash=item1e5135900b:g:e9oAAOxyuOtRbDYC .

This part costs $10.50 plus shipping. This price is plainly higher than it was a decade ago. It is good value for money!

Hope this helps.

Yours faithfully,

Spook

yea thanks i found it too...Hope that he is still well I called yesterday & havent got a call back,,hope Covid didnt get him, i like buying from small sellers like that

is there a part # for this??who sells this? there are 2 sizes right The supply line to filter &then the fwd line to engine?