While attempting to replace the sending unit in my wagon, I got to the part in the Bentley manual where it says very simply, "remove the hoses on the top of the unit". Line to the fuel pump has a clamp - no problem. The return line however won't budge. As I get more and more agressive with it, it is apparent that there is some kind of inner sleeve and there is no way to remove it without damaging it. "Well", I thought, "the sending unit is never going to come out with that hose attached", so I cut the line and the plastic hose inside it. Got the sending unit out (with difficulty) and now have to figure out what to do about the return line with the fitting.

I bought some high pressure fuel line that the plastic line fits into snugly and I intend to just clamp it off at the fitting end and put a coule of them where the plastic was cut, then clamp it to the sending unit. (Overall, there will be about 3/4 inch (max) that will not have the plastic "liner"). Is this a bad idea? How "special" is that line from Volvo? Is the pressure really that high even on the return line? How else does that ever come off?? I can find no mention of it in my searches here.

And while we're at it - I found that the "fuel overfill" hose was torn. It looks like it was attached to a plastic junction box above the axle. Is this correct? What is the box?

And finally, while getting the return loose, I tore a small clear tube that looks like some kind of drain tube, but attaches to a nipple on top of the axle. What is that and do I need to replace it? (Comedy of errors, I know!).

Any tricks to getting the sending unit smoothly into the opening? I thought that after replacing my wiring harness this would be a breeze, but as always each repair has its' own set of challenges.

Any advice will be greatly appreciated,
Craig

'84 245, 285k and getting newer part by part