Re: Fuel Return Leaking - Saab Saab Model 99 Bulletin Board - Saabnet.com
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Sadly I think that's a fairly common problem at this point. Luckily, that is the return line, so it's not under (much) pressure. I think you will have to carefully cut off the plastic line where it goes into the crimp and then find a piece of rubber fuel line that will fit securely over the remaining plastic line (I seem to recall that there's not much length of the plastic line to work with) and then clamp your new bit of hose to the plastic line (maybe use two clamps if they will fit, I prefer the "fuel line" clamps which have the full circle of flat metal around the hose rather than common screw clamps). Then the other end of your bit of hose goes on the check valve (there's a metal one intended for diesel that makes a good replacement for the leaky Saab plastic one, I think we've talked about that here before. For good measure you may want to roughen the outside of the plastic line and apply a bit of permatex or other fuel sealer before putting the rubber hose over it (just to ward off evil spirits). As an alternative you could carefully use a Dremel with cut-off wheel to cut away the crimp band and pull the old hose off. That might give you more length of the plastic hose to work with, but you will likely still need to clamp on the new rubber hose. I have cut the crimp off of various fuel injectors (including Saab D-Jet and Jaguar Bosch/Lucas) with a Dremel and that worked pretty well. Just be careful not to nick the plastic hose underneath! Good luck with the repair, let us know how it works out.
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