Today I decided to replace my leaking supply line at my tank.

It was a very dirty job that ended up taking me an hour and a half, mostly due to stuck lines due to corrosion and old age.

I ordered a tank screen and the supply and return line from Fastlane.

The tank screen requires a 46mm socket so be ready for that.

You will also want to have on hand two new hose clamps as the old ones are most likely junk at this point. There is also a copper washer on the return line so you may want to replace that as well, my new line did not come with one.

First thing to do is drive the car until the tank is empty or very very close to it. Fortunately my tank was already empty due to the leak (yes I caught the leak in a pan).

Next chock the wheels and jack up the car on the passenger side rear jack point.

Get down there and have a look up above the passenger side half shaft, you'll see two lines coming out of a triangular rubber boot.

The first thing I needed to do was cleanup a little just so I could see what I was working on.

Then I got myself a drain pan and slid it down under the lines in anticipation of additional fuel. Even with an empty tank I would guess that another quart or so of fuel came out when the lines were off. With that fuel splashing around you may want safety goggles instead of glasses for this job. And definately some rubber gloves (neither of which I had but I know I should have ).

Next I attempted to unscrew the hose clamps but mine were too gummed up and rusted for a screwdriver so I got a pair of pliers (channel lock's would work too) in there, clamped down on the screw head and turned it that way.

I only had to loosen the clamps slightly in order to pull the soft line off of the hard line.

After getting both lines off at the hose clamp end and letting the fuel drain completely I decided to go ahead and cut the lines right at the fitting at the tank. That allowed me to get a 19mm deep well socket onto the fittings.

My supply fitting was incredibly difficult to loosen from the tank and after I got it out I realized why; the tank screen came with it.

I never did get my old line off of the tank screen but judging by the type of fitting that it is I don't think there was supposed to be a copper washer between the two. Please correct me if I'm wrong.

After removing both lines from the tank (both 19mm) I pulled the protective rubber boot off and cleaned it up.

I then screwed my new tank screen in and attached my new supply line to it.

The return line has a sort of washer on it that acts as a retainer for the rubber boot so I slid the rubber boot over the supply line and then inserted the return line through the boot and torqued it down.

The boot then needs to be pushed into place as it has a valley where the sheet metal fits into it to hold it in place.

Next, slide your new hose clamps on, route the return line through the mounting point and onto the hard line. Push the supply line onto the other hard line, paying attention to which line goes where.

Tighten the hose clamps down and you're done.

I haven't yet started the engine using the new lines so I'm not sure what to expect as far as purging the air in the lines.

Good luck!

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1987 300SDL 167k
1992 Volvo 740 140k
1990 Volvo 740 250k
1989 Volvo 240 269k

Anyone want to trade an old Volvo for an '87 300sdl?