Volvo Cars 1999-05

Fuel Injectors

Print

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Injector connectors
     
    Fuel rail with injectors attached
     
    Injector mounting rail
     
    Injectors
     

  6.  

To install:

  1. Install or connect the following:

    Injectors to the injector mounting rail
     
    Fuel rail
     
    Injector connectors
     
    Intake manifold
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

4- & 5-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel rail cover
     
    Injector connectors
     
    Fuel rail mounting bolts
     
    Fuel line quick-release connector using tool 951 2666
     
    Fuel rail with injectors attached
     
    Injector mounting rail
     
    Injectors
     

  6.  


    Click image to see an enlarged view

    Fig. Injector removal

    Injector removal

To install:

  1. Install or connect the following:

    Injectors with new O-ring seals
     
    Injector mounting rail
     
    Fuel rail. Tighten bolts to 84 inch lbs. (10 Nm)
     
    Fuel lines
     
    Injector connectors
     
    Fuel rail cover
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the hoses between the turbocharger/charge air cooler and air cleaner/turbocharger on turbocharged engines.
  6.  
  7. Remove the upper section of intake manifold on non-turbo engines.
  8.  
  9. Remove or disconnect the following:

    Injector connectors
     
    Fuel rail
     
    Fuel line quick-release connectors using tool 999 5666
     
    Injector mounting rail
     
    Injectors
     

  10.  

To install:

  1. Install or connect the following:

    Injector
     
    Injector mounting rail
     
    Fuel rail and tighten mounting bolts to 33 ft. lbs. (45 Nm)
     
    Injector connectors
     

  2.  
  3. Install the upper section of the intake manifold with a new gasket on non-turbo engines.
  4.  
  5. Install the hoses for the charge air cooler and air cleaner on turbocharged engines.
  6.  
  7. Start engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Mass Air Flow (MAF) sensor connector
     
    Idle Air Control (IAC) valve connector and hose
     
    Air intake hose
     
    Throttle pulley cover
     
    Throttle Position (TP) sensor connector
     
    Accelerator cable and bracket
     
    Cruise control servo
     
    Throttle body vacuum hoses
     
    Injector cover
     

  4.  
  5. Install fuel injector holders on the injectors.

    Fuel pressure regulator vacuum hose
     
    Fuel supply manifold with injectors attached
     

  6.  
  7. Remove the injector holders and separate the injectors from the fuel supply manifold.
  8.  

To install:

  1. Install or connect the following:

    Injectors to the fuel supply manifold with new O-ring seals
     
    Injector holders
     
    Fuel supply manifold with injectors attached. Remove the injector holders.
     
    Fuel pressure regulator vacuum hose
     
    Injector cover
     
    Throttle body vacuum hoses
     
    Cruise control servo
     
    Accelerator cable and bracket
     
    TP sensor connector
     
    Throttle pulley cover
     
    Air intake hose
     
    IAC valve connector and hose
     
    MAF sensor connector
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

5-Cylinder Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Injector cover
     
    Accelerator cable
     

  4.  
  5. Install fuel injector holders on the injectors.

    Fuel pressure regulator vacuum hose
     
    Fuel supply manifold with injectors attached
     

  6.  
  7. Remove the injector holders and separate the injectors from the fuel supply manifold.
  8.  

To install:

  1. Install or connect the following:

    Injectors to the fuel supply manifold with new O-ring seals
     
    Injector holders
     
    Fuel supply manifold with injectors attached. Remove the injector holders.
     
    Fuel pressure regulator vacuum hose
     
    Accelerator cable
     
    Injector cover
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

 
label.common.footer.alt.autozoneLogo