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1992 Volvo 240 sedan - fuel line leak (spray!) 200

posted by  iamhives on  Mon Jun 27 13:43 CST 2016
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last visit: Sat Sep 6 22:19 CST 2014
[RELATED]

My wife reported a strong gas smell. For her to notice it must be bad. Sure enough the fuel sprays (about 3 ft!) out of the larger of the rubber lines in front to the fuel filter/pump when running. I assume this is the high pressure feed to the fuel rail. I've had a replacement fuel filter in my garage for a couple of years so i guess now is the time to install it.

Regarding the fuel line that obviously needs replacement. Looks like the original part is unavailable so I'll have to make my own from pipe and the original fittings? Done some searches and haven't found much. Questions:

1) Am I correct that the complete fuel line assembly is unavailable?
2) Assuming I do have to fabricate my own does anyone has links to instructions
3) What size/type of fuel line (OD/ID) do I need and what is a source - FCPGroton seems to have several sizes. What length is needed from the fuel filter to fuel rail?
4) Do I just press in (with heat?) the two fittings into the tubing?
5) Could I just splice in a small section using a barbed fitting or is this considered too much of a 'kluge' - I'm guessing it is since we're dealing with gasoline.

Any other pointers?

Thanks






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