Injector/pulse damper, replacement

Preparation

Empty the fuel injection system according to Fuel system pressure release .

Fig 1: Charge Air Pipe Over Engine

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the charge air pipe over the engine. Seal the openings

Fig 2: Fuel Rail

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the cover over the fuel rail.

Disconnect the injector connectors.

Blow clean around the injectors.

Remove the mounting screws from the fuel rail.

Open the fuel line's quick-release connector using tool 9512666 .

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

Gently work the fuel rail and injectors loose.

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

Removing injectors

Remove

Removing the pulsation damper

Remove

Installing injectors

Lubricate the injector O-ring with a thin layer of petroleum jelly.

Install the new injector.

Installing the pulsation damper

Lubricate the new pulsation damper O-ring with a thin layer of petroleum jelly.

Install the new pulsation damper.

Finishing

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. Tighten to 6 Nm .

Fig 3: Fuel Rail

Courtesy of VOLVO CARS OF NORTH AMERICA.

Lubricate the injector O-rings with petroleum jelly.

Depress the fuel rail. Ensure that all injectors sit correctly.

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

Connect all the connectors for the injectors.

Press the quick-release connector together until a clicking sound is heard.

Reinstall the cover over the fuel rail.

Fig 4: Charge Air Pipe Over Engine

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the seals from the charge air pipe. Reinstall the charge air pipe over the engine.

Start the engine. Check for fuel leakage.