1994 940 turbo sedan 97K

I have a fuel leak in the steel line carrying fuel from the tank to the fuel pump. It is due to corrosion. Several other portions of this line in the same area show potential for additional rust through.

The bad portion is tucked up above rear suspension brackets and the exhaust system.

I would like to think that since this line is relatively low pressure (between intank and main fuel pump) I might be able to cut out the bad section and bypass it with fuel hose and clamps.

The OD of this line is about 7/16", or 11.5mm.

Any suggestions on dealing with this problem would be appreciated.

Randy

Thanks for everyone's responses and suggestions.

I went for the quick fix. I cut out the bad section of the steel line from tank to main fuel pump. I replaced it with a length of 7/16" fuel hose. In the process of removing the bad section the 5/16" (8mm) return line beside it started to leak in a rusted area. A section of 5/16" fuel hose repaired that.

Things are good for now but corrosion is a non stop issue so we will see how much time I bought.

I would have normally made the cuts in steel lines with an abrasive disk on a die grinder but of course the sparks it generated would have made for a bad combination with the gasoline that exited the cut lines. The work space was limited. Removing the exhaust system behind the cat would have been helpful as would have removing the gas tank. I was able to get a pneumatic saw into the necessary positions to make the cuts to the existing lines.

Randy

I would think that fuel injection hose would be your best, and easiest, solution. After clamping it to what is left of the fuel line, assuming not all of it is rusted out, you can zip tie it so it will not flop around.

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Keeping it running is better than buying new

Dear rstarkie,

Hope you're well. If I recall correctly, lucid (on whom be Peace), reported how much hard work was involved in replacing that length of steel pipe.

Given the exposure to road hazard, might it be advisable to use stainless steel mesh to sleeve fuel hose? The steel mesh will protect against many road hazards. I used stainless mesh to sleeve heater hoses, which are hard to inspect because of location and because hoses usually erode internally and then burst. My goal was to avoid a defect-caused hose blow-out and sudden coolant loss. So far, so good.

Alternatively, could the failed section be replaced with steel tube, joined by compression fittings? There are 7/16" brass compression fittings. While these are made for use on copper tube, I'd bet they'd work on steel. If the steel fuel pipe's diameter is slightly under-size, a sleeve could be soldered to the cut-ends, so that the compression fitting will grip properly.

Hope this helps.

Yours faithfully,

Spook

When replacing the 15.8 gallon tank in earlier 740/940 series with the 19.8 gallon tank from the 1993+ 940 series, I have replaced this line with fuel hose. I made sure it was well secured with clamps or plastic ties. Never had a problem in many years of service.
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john