It is a bit tricky to do right. And I can tell from your post, you really do want this done right.
Did your mechanic tell you what happened to the nylon pipe? I've never heard of one dying without having suffered some mechanical abuse. Good to know why it happened.
Don't assume it is not available from Volvo. Some for the later cars are indeed NLA (no longer available), I hear. I believe it was sold as an assembly -- both ends already attached. Give your dealer's parts guy a call and have your VIN handy.
Take a look at this. You can see the "mechanical abuse" I provided to one of our cars. :)
240 Volvo Fuel Line Fun
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Art Benstein near Baltimore
A boiled egg in the morning is hard to beat.
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