Yesterday I replaced the fuel filter and check valve on my 1989 740 Wagon. I bought the fuel filter, check valve and the output copper gaskets on line but had to buy the 2 input copper gaskets ($4.65) from the Volvo dealer. The guy in the parts department told me to be sure to line up the holes in the banjo bolt on the fuel filter with the short fuel line that runs between the fuel filter and the fuel pump. He also said to do the same for the output banjo bolt. He claimed this is necessary to maintain proper fuel pressure in the gas line. I tried doing this but found the output nipple was in a position where I could not connect the fuel line - either striaght up or inside the cage. I never read anything about this in the Forums or the FAQs. There is a channel in the part of the output nipple that the banjo bolt goes through for the fuel to flow through so I adjusted the position of the output nipple so I could connect the fuel line. Seems to me the parts guy has given me bad advice - is that true?

One other thing. I had to cut the fuel line to remove it from the fuel filter. The neophrene lining stuck to the nipple and couldn't be pulled off. I now have a shorter fuel line that is bearly long enough - I took up the slack to make the connection at the fuel filter. Now the fuel line can easily be removed from the nipple at the fuel filter and I'm concerned it may disconnect while I'm driving the car. Will this in time adhere to the nipple as the former connection did? I am also considering buying a short piece of fuel line and splicing it to the existing fuel line with a brass connector and 2 clamps to lengthen the fuel line. Does this seem reasonable? If so what is the ID of the high pressure fuel line?

Your answers and advice are greatly appreciated - thanks

Wally