Volvo Truck 2003-05

Fuel Injectors

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Removal & Installation



6-Cylinder Engines
  1. Drain the fuel injection system.
  2.  
  3. Remove the plastic hoses between the turbocharger and charge air cooler and the air cleaner and turbocharger. Place them to one side and seal the openings.
  4.  
  5. Remove the protective cover above the nozzles
  6.  
  7. Disconnect the connectors from the injectors
  8.  
  9. Remove the mounting bolts from the fuel rail
  10.  
  11. Spray universal oil or similar around the injector terminals on the intake manifold.
  12.  
  13. Gently work the fuel rail and injectors loose.
  14.  


NOTE
Handle the injectors carefully to avoid damage to nozzles and needles.

  1. Remove:

    The bolts holding the mounting rail to the fuel rail
     
    The mounting rail
     
    The injector.
     

  2.  

To install:

  1. Lubricate the O-ring for the new injector using petroleum jelly.
  2.  
  3. Install the injector.
  4.  
  5. Position the mounting rail. The injectors may need to be pulled away from the fuel rail a few millimeters to install the rail
  6.  
  7. Tighten the mounting rail to the fuel rail
  8.  
  9. Press down the fuel rail.
  10.  


NOTE
Ensure all the injectors are correctly positioned.

  1. Screw the fuel rail into place. Use new bolts. Tighten to 84 inch lbs. (10 Nm)
  2.  
  3. Install all connectors on the injectors
  4.  
  5. Press the fuel line quick-release connector together until it clicks
  6.  
  7. Install the cover over the nozzles
  8.  
  9. Remove the seals. Install the plastic pipes between the turbocharger and charge air cooler and the air cleaner and turbocharger.
  10.  

5-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions 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.  


    Click image to see an enlarged view

    Fig. Injector removal

    Injector removal

 
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