I have a fuel leak and I think its the small 9" rubber coming from the fuel filter to the main fuel static line to the engine. I checked out the FAQ on the subject and it said just buy a gas rubber hose or better yet buy it from a dealer for right sizing. today the dealer wanted to sell me a $78.00 part - I think it was the rubber hose and fuel line to the engine. he sid you can't just replace the rubber hose. I passed. I checked all the volvo parts sites and came accross http://www.volvopartswebstore.com/showAssembly.aspx?ukey_assembly=235169

and got even confused more.....

I have a 96 960 wagon B6304F the leak is on the driver's side of the unit where the rubber hose is easily seen.

does the rubber hose slip off the sleeves of the nuts and such and it can be easily replaced once I get it off - or should I buy a complete kit or something? can someone direct me to a site to buy the right part.

She has 176,000 miles and still purring.

Dear Domenic,

Hope you're well. I do not operate any 960. Volvo Vadis - the now-superseded dealer parts/service software package - shows the a fuel "pipe" at the front (driver's) end of the fuel filter. This is Part #6848813.

There seem to be two ways this "pipe" (a rubber or plastic hose) is connected to the filter. The first method is via a banjo bolt, a hollow, threaded bolt, through which the fuel flows. The second connection method involves a pull-release fitting.

This fitting has an outer sleeve that is pulled backwards (away from the filter) to release it. While the outer sleeve is held in the "pulled back" position, the fitting must be pushed forward slightly, to release it from the filter's nipple. This type of fitting is used on one of the connectors to the 940 fuel tank send unit.

Whichever fuel line-to-filter connection method is used, the front fuel "pipe" is Part #6848813. The cost is about $14. The fuel "pipe" on the other side of the filter (the side from which enters fuel from the tank) is Part #6848811. For no obvious reason, this part costs about $33.

I'd have thought that fuel hose, rated for "fuel injection use" (high pressure) could be used for either of these pipes. To ensure a tight fit, I'd use screw-type hose clamps to secure the fuel hose. I do not know the diameter of this hose, as it is not shown on the diagram.

Hope this helps.

Yours faithfully,

Spook

Spook -

I am so greatful that you responded to my post. I intend to buy part #6848813 and do the replacement with confidence. It's so amazing how a dealer can steer us all wrong sometimes. one last question, do you have any advice on what precautions I should take while working around gasoline - besides the obvious (don't smoke)?

Domenic
--
1996 965 145K

Dear Domenic,

Hope you're well. I've not had to work on fuel lines, only on fuel tank send units. Work on fuel systems should be done out in the open (i.e., not in a garage), where there are potential sources of ignition (light switches, etc.).

I'd have handy a fire extinguisher and rags, to soak-up any fuel spilled. Do not use any work light, if at all possible. If you must use a work light, to not operate the switch near the work area. Remove the light to a safe distance, and then operate the switch.

I'd remove the fuel pump relay (or fuel pump fuse), so that no one can start the car. If, for example, you have to leave the job in the middle for a few minutes, e.g., to deal with a parcel delivery, you do not want someone to try to start the car. If that is done, the pump will spray fuel out of the open line. This is a fire risk. I recall a post, in which it was reported that oil had been drained. There was an interruption. A family member, not realizing the car was being worked on, started the car....

When you open the fuel line, be prepared for some fuel to squirt out, as the system is pressurized. As you're working on a line that is between the pump and the the filer, the tank cannot drain, so only a few ounces of fuel should be involved.

Once you remove the failed "fuel pipe" clean all fittings to ensure a tight fit of the new "fuel pipe". Once you have installed the new part, take some dishwashing liquid and mix it with water (50/50). Apply this to the "fuel pipe" connectors (both ends). Remove any gasoline-soaked rags to a safe distance (50 feet / 16 meters). Start the car. If there are no bubbles of soap around the fuel pipe connectors, everything is tight. Dry-off the fuel pipe connectors.

Hope this helps.

Yours faithfully,

Spook