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K Jet fuel return line replacement 200 1982

posted by  runwld2 on  Tue Nov 12 02:31 CST 2002
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last visit: Tue Sep 30 13:11 CST 2014
[RELATED]

1982 242 Turbo
After having replaced the in tank fuel pump, every try at reconnecting to the return fuel line has resulted in another leak when the line cracks.
I have concluded I must replace the entire metal line fromthe firewall to just over the rear axle. The original is a 5/16 metal line with flared ends connecting to 1/4 inch hose. Volvo does not sell a replacement. Their option is buying 3 meters of tubing for $45! and flaring the ends and using the stock connectors (5/16 tube to 1/4 inch hose)
I have 3 options.
1-Replace with 1/4 inch rubber hose-easiest but is it safe?

2- Replace with 1/4inch metal pre flared tube pieces (3 needed), this is used because i can only find 1/4 flared to 1/4 hose connecters, but will this be too restrictive of fuel flow?

3-Replace with 5/16 metal and Volvo flare end connectors., this option means I must flare the tube ends myself (which I must by a tool for)

Has anyone done this repair?
--
744-16v,745-16v,242Turbo.245DLT






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