Injector/Pulse Damper, Replacement: Finishing

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2006 Volvo S80, 2005 Volvo S80, 2004 Volvo S80, 2003 Volvo S80, and 2002 Volvo S80. However, it is still accessible from the selected car via links, so may be relevant.

Position the mounting rail. The injectors may need to be pulled away from the fuel rail a few millimeters to install the rail.

Tighten the mounting rail to the fuel rail.

Press down the fuel rail. Check that all injectors are correctly positioned.

Screw the fuel rail into place. Use new screws. Tighten to 10 Nm .

Install all connectors on the injectors.

Press the quick-release connector together until a clicking sound is heard. See Fuel line, lock .

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

Courtesy of VOLVO CARS OF NORTH AMERICA.

Applies only to B6xx4T . Remove the seals. Install the plastic pipes between the turbocharger (TC) / charge air cooler (CAC) and the air cleaner (ACL) / turbocharger (TC).

Fig 2: Identifying Upper Section Of Intake Manifold

Courtesy of VOLVO CARS OF NORTH AMERICA.

Applies only to B6xx4S engines . Remove tool 999 5723. Clean the gasket faces and install a new gasket . Install the upper section of the intake manifold. Tighten to 17 Nm . Start from the center and tighten alternately.