I'm planning on installing a new fuel tank sending unit (with a new in tank pump, gasket, lock ring, etc) this weekend. My prepump is dead, and everything is totally rusted (16 years in MA and Jersey). I'm pretty sure that I can just buy new low pressure line to replace the line between the tank and the main pump. What is the best way to reconnect the high pressure fuel return line to the sending unit? I don't want to replace the entire fuel return line (this is the line that returns gas from the fuel rail...I believe it's still around 40 PSI). I believe this line has a plastic inner core. Any suggestions or ideas would be much appreciated.

-instant

The return line is not High pressure.

For the method I have used on many sender replacements, see my response to your thread of October 23rd.
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Bruce Young
'93 940-NA (current), 240s (one V8), 140s, 122s, since '63.

Replacing both hoses is by far the easiest way to do it. You can buy fuel injection rated hose for the return line at any auto parts store.

John

There are quite a few posts about this floating around, so you could search for those. Basically the fuel return is low pressure (it's gone by the pressure regulator), so any fuel line will do. The trick is getting the old line off. There is a connector there, but it's probably so rusty and hard to get to that you will wreck the fuel line trying to get it apart. Just cut the rubber hose where it goes on the plastic covered line. It's a barbed fitting so you can slit it where it attaches and pull it off, gently, you don't want to break that solid line!. Then throw that mess away and use hose clamps to attach new hose from plate on tank to fuel line.
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744 & 745 16v 4+OD, 245 SE auto, 242Ti 4+OD, 745 8v auto

If you have the part in hand...pay a local independent Volvo oriented mechanic to do the job. How much is your time worth, gas spraying all over the place if you make a mistake, included.