I followed the FAQs and tried to change my dirty fuel filter today at my friend's shop. I pulled the fuse but the engine died right away, so I just closed my eyes while I loosened the connections.

I bought the "correct" filter from CarQuest. It came with some kind of adapter already screwed into the "out" side which was not the same size as the fitting on the car, so I had to remove it, but it was fastened with Loctite or something.

Also, it only came with 2 copper washers instead of the necessary 4, so I had to reuse 2 of them.

I started it up and it looked OK, but by the time I got home, it was leaking. I'm done with this project, I'm taking it to the mechanic on Monday.

UPDATE: The reason it was leaking is one of the bolts sheared in half inside the banjo bolt. The threads are stuck in the filter. Now I'm really screwed (pun) because it's Saturday night, so I have no car until Monday when I can beg a ride and go to Volvo to get a new one. Rats.

When you install the new one, use some antiseize on the outside six or eight threads to prevent corrosion from bonding all the threads inside the filter. Just a little will stop a huge problem later.

Thanks for the responses. I have to throw a FRAM on it because I need to drive the car, but I will get a genuine Volvo one. BTW, CarQuest charged me $41... the FRAM was $21 and included all the right gaskets.

Yeah, the CarQuest filter is wrong; BT,DT. I WILL work, if you take off the fitting and have all new gaskets.
Try one of the Parts Bin outlets; i.e.: alloemvolvoparts.com, or RPR, FCP, etc.
Insist on the copper gaskets as well; RPR will ask.

Bosch and OEM Volvo filters are both correct for the car and come with all necessary washers. I would never use a generic aftermarket filter when the real ones are so cheap and easy to get.

From 240 experience I know the fuel filter is not a routine shadetree job as it used to be on my carb'd US cars or even the Japanese cars.

But the filter is so big I'll never change one again just for the heck of it - I'll wait for symptoms, rust or some kind of abuse.

The job (on the 240 LH cars) is frought with pitfalls; fragile plastic lines, under car access, needing to pinch the tank line. The banjo bolts really want an impact wrench.

I'd guess it may take 30-50 years to clog that huge filter.
--
Art Benstein near Baltimore

Next time try FCP Groton. OEM parts aren't that expensive and less work to install.
--
95 854T, 88 780, 88 245, 01 A4 Audi

Just did this same fuel filter job today, along with a gear oil change and exhaust on my 88 740 project. Took my time, had bought a bosch filter for $10 - 4 crush seals for another two bucks.

Carefully took the bracket with pump down. Pinched the main fuel hose to the pump and proceeded to take off the clamp. Of course the clamp fell apart from rust (was expecting that) had a small clamp in stock. Pulled the pump and assembly out from the car a bit and used air to take off the banjo nut.

Put the entire unit on the bench and used air to take other side off (with PB blaster). The clamp holding the filter wanted to collapse from rust and bolt did not want to come out. With luck, I saved it and re-assembled with a new filter and new crush type seals (keep several in my parts drawer), put whole unit back up and tightened both banjos securely. Scraped off all remains of old clamp on the hose to the fuel pump and put a new clamp on - made sure yellow wire went on yellow connection on the pump!

Bolted it back up and put a pan under the car before starting it! Immediately checked for leaks - and yes! No leaks. Of course, I have done other fuel filters with more problems - like not clamping the hose correctly and pouring gas on the floor and had one leak like a gusher on startup! Not my favorite job - but it is do-able! My garage charges $15 labor to put on - but if they run into the rusty filter syndrome - might be more. I spent about 35 minutes doing this one.

Had a good volvo day - put on an exhaust, changed gear oil, fuel filter and swapped out a front fender (interesting job there) but the exhaust needs some tweaking and I still have an oil drip after replacing a oil pan gasket!

Bottom line - leaks of any sort - oil or fuel are no fun!

Bob Weber
Hamilton, Ohio 45013
59 Volvos since 1979