My son made a rookie error and ended up cracking one end of the hard nylon fuel line between the fuel filter and the fuel rail in his 940. Most Volvo RWD cars use a very similar configuration: a 6mm ID/8mm OD nylon line surrounded by a protective rubber hose, with one end pressed into a banjo fitting and the other into a swivel fitting and nut. Volvo no longer offers this line for 940 cars although they "may" have a compatible part made for 240 cars. We decided to fix it ourselves. Art Benstein's notes helped materially.

1. Remove the line from the car and carefully slice the rubber hose cover so you can repair the line. You can reuse the cover using zip ties.

2. If the break is right at the fitting, you are in luck and you can reuse the nylon line. If not, Ford makes an EFTE polyamid line in the same size that you can get from any Ford dealer. Not cheap, but it is high temp/high pressure, something that many aftermarket nylon lines are not.

3. CAREFULLY slice off the fitting, making sure not to score the metal. Use an Xacto knife with the cutting blade pointed toward the nylon, not the metal, to score it. Use a plastic putty knife to open the score. Cut off the nylon cleanly at the end of the fitting.

4. To reinstall, you will need to press the fitting back in. Forget about YouTube advice on using boiling water or a heat gun. Instead, make a block holder for your vice by drilling an 8mm or slightly smaller hole down the middle of two parallel lx2 sticks. Sand these down so the two blocks and their hole grip the nylon tubing very tightly (but not so much you fracture it) when the vice is closed down.

5. Take a socket that will fit over the end of the fitting. Mount an extension on the socket. Mount the nylon in your block so that about 1/2 inch is exposed when you tighten the vice. If you can, flare the end of the nylon a little using a metal cone (like on a flaring tool).

6. Lube the inside of the nylon with a little oil spray or WD40. Carefully press the end of the fitting into the tube, being VERY careful not to kink the end. Use a rubber mallet to tap this home. Stop, loosen the vice, and pull out another 1/2 inch of tubing. Tap some more until the fitting is fully seated. Make sure it does not fold over and kink.

7. Either reinstall your protective rubber sheath or a length of vacuum hose with zip ties, and remount it in the car.

Your line has enough slack so that removing an inch at one end is not a problem. If you need to replace tubing closer to the middle, just buy an all-new tubing line.