title Disconnecting fuel line from filter, why does volvo use fuel connectors from hell ? (And how to disconnect them ?)

Hi,

I have a XC70 03 with leaking rusted fuel filter

Got a new filter, tried to replace it but it didn't work as I'd hoped.

On the fuel line connectors, there are gray tabs that you're presumably supposed to press to release the hose.

I pressed them, the hose turns but it doesn't release. Got in a better position, pushed as hard as I could with my fingers, I cut myself a little, push-pull-twist-yank-push-pull and so on, it just won't let go

I squirted a bunch of penetrant lubrication fluid into the hose connectors

https://imgur.com/ql675vX


https://imgur.com/LhS03c4

I tried squeezing it with the vice grip, but that doesn't squeeze the tabs, it just holds on to the connector's body

https://imgur.com/SJYJHh9

I tried the smaller vice grip but same thing

https://imgur.com/OWFtKg9

I tried wrapping zip ties around it and squeezing the heads of the zip ties onto the gray tabs

https://imgur.com/8Ssdo4S

But the awkward position, trying to juggle the zip ties, the vice grips and everything was just too much !

So I had the idea to put tape around the connector

https://imgur.com/Uo6iU39

And then stick the cut heads of the zip ties in place

https://imgur.com/Iin6cW7

Now I've got them good on there !

https://imgur.com/GX4Omwp

push-pull-twist-yank-push-pull again, but it won't budge, it does turn just fine but it won't come out ! Yes, I tried pushing hard !

The tabs are pushed in permanently now, I wonder if that's going to be an ever bigger problem ?

https://imgur.com/lN0nkiw

I went on youtube and the forums, looking for the trick maybe ?

--------------
youtube and forum results here


A video showing you should be able to take it off with just your hands

this video is from an XC90 but it's the same setup

Another video showing just how dam easy it is supposed to be

fcpeuro, showing again that it's super easy

these guys are using some tool

this person has the same problem, pushed on the buttons using open end wrenches
https://volvoforums.com/forum/volvo-...t-stuck-60568/

this person used jumper cable clamps
https://volvoforums.com/forum/volvo-...el-pump-50495/

this person gave up and brought it to the dealer
https://volvoforums.com/forum/volvo-...onnects-70542/

this person didn't resolve their stuck fuel filter, suggested using a special tool or going to dealer
https://www.matthewsvolvosite.com/fo...ter+disconnect

this person did the fix, and then it blew out the lines under pressure, suggest
https://www.matthewsvolvosite.com/fo...c.php?p=599775

This post also mention they are hard lines covered with rubber so you can't just cut them and clamps
https://www.matthewsvolvosite.com/fo...c.php?p=448365

This person cut the line, discovered they are hardlines, they have not been heard from since and are presumed dead
https://www.swedespeed.com/threads/2...nnects.656305/

This person says "couldnt be easier"
https://www.swedespeed.com/threads/f...easier.354018/

This person's mechanic broke the connectors and replaced with generic screw hose clamps, are worried about leaking gas on the exhaust
They reported putting 1000 miles on the car, they have not been heard from since and are presumed dead
https://www.swedespeed.com/threads/f...-v70xc.218735/

This person broken the fuel filter connector, paid 990$ plus towing to have it fixed by replacing the entire line
https://www.swedespeed.com/threads/f...1/#post-894536

This person says to squeeze, push then pull
https://www.volvo-forums.com/threads...390/#post-3281

This person also tried everything in 2009, they have not been heard from since and are presumed dead
https://www.volvo-forums.com/threads...8/#post-112439


I see on ebay, there are special pliers that might do it ?

https://imgur.com/Hac0Wbz


https://imgur.com/5jqb3VK


--------------

my friend lended me his dad's hose disconnect tool kit as well as a pep talk

https://imgur.com/4GHgV8y

I tried the 1/4" tool

https://imgur.com/mZ7hiVt

I tried the 5/16" tool

https://imgur.com/32ReE62

I tried the filter inlet side, that's the leaking side, it broke off immediately

https://imgur.com/yzwk3Vq

https://imgur.com/cclaFBg

It's not budging, mosquittos are eating me alive and it's 3AM so I'll try again tomorrow


Another day, what we're looking at here

https://imgur.com/CKPaYbr

https://imgur.com/6ZeBbQe

1/4" tool again, it's in the "out" position

https://imgur.com/iKrRZOH

1/4" tool, in the "in" position

https://imgur.com/Tj71yZX

Trying to have a look inside the connector

https://imgur.com/PS8E6fS

https://imgur.com/6PhHowN

Trying the 5/16" tool again

out position

https://imgur.com/Gg75DNx

in position

https://imgur.com/6Azss9r

Trying another tool that fits

https://imgur.com/HkARy0i

I can hear clicking sounds, but it's not moving

https://imgur.com/gcpDU89

I tried with the zip tie heads again

https://imgur.com/DBIk4hv

https://imgur.com/HN0kFkd

It's well squished

https://imgur.com/gDVoTtr

And I've got another tool to help me pry the connector from the filter

https://imgur.com/9IXFJMf

Well, I'm stuck, I also tried heating the line with a hair dryer, but no effect

I ordered the two fuel line disconnect tools off ebay, I hope they will arrive before the end of next week !

Is there any way to buy replacement hose end connectors, so I could just cut off the lines and push in new connectors ?

I really really really don't want to change the lines, especially not the line that goes to the fuel pump !

I've seen that you have to cut a hole in the floor or drop the subframe to get at the fuel pump so .

 

They do that for ease of assembly.

With the tool, you typically have success. They generally work. You typically have to push the connectors toward the filter a bit to unload the pressure on the locks. Pushing away does not help. All that stuff is repairable, but boy, do I hate repairing it. It is torture. So try not to break anything.

From the looks of those vice grips, you may be defeating yourself by pulling. Everything there needs to push in to unlock.