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I finally broke a fuel pump’s 90 deg plastic fuel line fitting from my daughter’s 1999 9-3. It is the black return one. I have always taken seriously the warnings from many of you and successfully replaced four pumps until now. What surprised me is that the fittings came out of the old pump well (with much care) but was very difficult going into new one and broke as it was almost home. Maybe after market inside diameters were slightly smaller or maybe because I had the 90deg fittings out of old pump for a couple days before inserting into new pump that the o-rings swelled. My first cry for help is regarding the picture (link below) of the remaining fitting that I don’t seem to be able to pull out of the new pump. I tried grabbing it with one and two needle nose pliers but it is in tight as I could see the pump lid flexing upwards. I have thoughts of drilling it out or maybe tapping it and then putting in a screw and trying to pull it. When I hopefully get it out, I was going to replace it with the black return fitting from a totaled 1997 9000 parts car I have. After reading several postings, it sounds like I can cut the hose at the broken fitting end and leave a couple inches of line on the used one from the parts car and connect with a barbed brass fitting by using a brake flaring tool (I never used one but will buy and try). I assume that the barbed fitting won’t choke the flow too much? Someone also posted that they just butted the two cut fuel lines together with a close fitting larger line around them and clamped. Any comments are much appreciated! ToddH
posted by 71.207.25...
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