Injector/Pulse Damper, Replacement: Preparation

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.

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.

NOTE:

Handle the injector valves carefully to avoid damaging the injector valves' nozzles with needles.