Injector/Pulse Damper, Replacement: Preparation

Fig 1: Identifying Plastic Hoses Between Turbocharger, Charge Air Cooler & Air Cleaner/Turbocharger

Courtesy of VOLVO CARS OF NORTH AMERICA.

Drain the fuel injection system. See Fuel system pressure release .

Remove the plastic hoses between the turbocharger (TC) / charge air cooler (CAC) and the air cleaner (ACL) / turbocharger (TC). Place them to one side and seal the openings. Applies only to B6xx4T  .

Fig 2: Identifying Upper Section Of Intake Manifold

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the upper section of the intake manifold. Cover the hole using tool 9995723 . Only applies B6xx4S engines  .

Remove the fuel rail.

Disconnect the connectors from the injectors.

Remove the mounting screws from the fuel rail.

Separate the fuel line's quick-release connector, see also: Fuel line, lock . Use tool 9512666 .

Spray universal oil or similar around the injector terminals on the intake manifold.

Fig 3: Identifying Injector Valve

Courtesy of VOLVO CARS OF NORTH AMERICA.

Gently work the fuel rail and injectors loose.