Our trusty rusty '86 wagon began seeping gas from the fuel line about mid-ship after 16 Wisconsin winters. I would prefer to replace the most exposed, lowest section of line, as the whole section that runs along the undercarriage looks about shot. Of course the line twists and turns, so fitting and bending the rigid line from the parts store doesn't seem feasible. Flexible neoprene line is supposedly out because of the line pressure (40-80 p.s.i.???) necessary to feed the fuel injectors. Does a flexible stainless steel line exist which could be spliced with compression fittings? Would it be easier (for some at least) to skip the splicing and replace the entire line?

Surely this is not a unique problem to this vintage Volvo, yet searching the archives yielded a flood, fuel-fumed, of extraneous problems. Anyone have a suggestion on further refining the search string "fuel line replacement" or "fuel line leak."

Thanks a bunch!!!

The high pressure fuel inflow line runs from the fuel filter to the fuel distribution rail. There is a "banjo" fitting at the fuel filter and a compression fitting at the fuel rail. If you had a leak in this line, it would spray to high heaven and you would lose gallons of fuel very quickly

The return line handles less pressure and so a crack in the line will often only drip. The return line begins after the fuel pressure regulator (FPR). The FPR is located at the end of the fuel rail nearest the front of the car.

Buy a Haynes manual. It has clear pictures and is well documented.

Bob

Any aeroquip supplier can give you the fittings.

The aeroquip line is good to what, 600+ psi? so you can use it pressure or return side.

Have you checked with volvo as to whether the stock fuel line, bends and all, is available?

OTOH, bending fuel line is trivial after a little practice and with the right tools, even the coils-over-tubing type of bender works well on brake line...fuel line is generally a lot easier. And it looks sooooooo stock.

Thanks for the reply John1234!
Several messages in the archives indicated that fuel line is "NLA" from Volvo, and complete sets of fittings and line are worth their weight in gold.

What is Aeroqip? Would the parts stores stock it? What constitutes the "right tools"?

Did I mention I am a change the oil or send it to the mechanic kinda guy?

I should emphasize that this is a back-up vehicle, much abused by Wisconsin weather and loads of kids. "Sooo stock" isn't important...getting it back on the road for a minimal investment is.

Thanks again!

Check to see if this is the return fuel line. If so, it's low pressure so carburator fuel line is fine. What I've done is replace the bad part with fuel line, cutting out the bad tube with a tubing cutter wheel. Get the nice fuel injection hose clamps (band-type).

Rene

Thanks for the reply Rene!
How do I determine if this is the return line? The Chilton manual was no help. The line is located on the driver's side, and now has a foot long section removed. When the engine was running, the fuel dripped, indicating low pressure???
Thanks again!

I don't think any of the high-pressure side is tubing, it's all hose. The tube is the return.

Rene

Hi Rene,
The news is getting better! Just for clarification purposes, the high pressure side is in hose, the pliable neoprene sort. The low pressure return side is in tubing, the rigid metal walled sort. This would explain why gas wasn't jetting all over when the engine was running.

Thus, I ought to be able to splice with neoprene hose of the same i.d., and some good clamps...not pretty but you should see the underside of this Volvo.

Just for the sake of cosmic balance, I must mention that this Volvo has been a real workhorse, and at least twice a year the wife decides to sell her shiny Mini-van and rehabilitate the weathered wagon!

Thanks for all the great advice. I hope to handle it from here.

All the best,
Holmes

Your all clear! Good luck.

Rene