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Fuel Injector Replacement
 
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Pelican Technical Article:

Fuel Injector Replacement

Nick Czerula

Time:

2 hours2 hrs

Tab:

$300

Talent:

****

Tools:

Set of sockets, 10mm, flathead screwdriver

Applicable Models:

Volvo V70 (1998-01)
Volvo V70 2.4T (2001)
Volvo V70 AWD (1998-99)
Volvo V70 GLT (1998-00)
Volvo V70 GLT SE (2000)
Volvo V70 R (1998)
Volvo V70 R AWD (1999-00)
Volvo V70 T5 (1998-01)
Volvo V70 X/C (2001)
Volvo V70 X/C AWD (1998-00)
Volvo V70 X/C AWD SE (2000)

Parts Required:

Fuel injectors, fuel injector O-rings, fuel pressure regulator

Hot Tip:

Work with a cool engine and relieve fuel system pressure

Performance Gain:

Clean and even flowing fuel injectors

Complementary Modification:

Replace fuel filter

Volvo V70 models with a normally aspirated 5-cylinder engine utilize one fuel injector per cylinder. Each fuel injector is an electrically controlled solenoid which, when triggered by a pulse from the engine control module, sprays a precisely metered amount of atomized fuel directly into the cylinder head intake port. The ECM supplies constant power to the injectors; the injector opening is controlled by the ground side of the circuit. Since fuel pressure at the injectors is (relatively) constant, the length of time (in milliseconds) of grounding pulse from the ECM determines the amount of fuel injected.

Over time fuel injectors can become restricted or fail electrically. If you have an injector giving you a problem, I suggest replacing them in sets. This way you maintain an even flow from all the injectors.

The injectors' shared fuel supply is an aluminum fuel rail. To remove an injector, you have to remove the fuel rail with all injectors attached to it. Then disconnect the electrical connectors to all the injectors. Individual injectors are then separated from the fuel rail, as needed by removing one main securing plate. If you remove the fuel injectors for any reason (for example, to replace the intake manifold) and you plan to reuse the fuel injectors, replace all the fuel injector sealing O-rings.

It's a good idea to relieve fuel system pressure before beginning. This will minimize the amount of fuel spilled. The best way to relieve fuel system pressure is to remove the fuel pump fuse and run the vehicle until the engine stalls. This is described below.

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you're working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Do not work on your vehicle if you feel the task is beyond your ability.

Vehicle models change and evolve, as they grow older, so the vehicle shown in our illustrations may vary slightly from yours. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

The injectors' shared fuel supply is an aluminum fuel rail (red arrow).
Figure 1

The injectors' shared fuel supply is an aluminum fuel rail (red arrow).

Working at the side of the fuel rail, remove the fuel pressure test port cap (red arrow).
Figure 2

Working at the side of the fuel rail, remove the fuel pressure test port cap (red arrow).

Using a flathead screwdriver and a rag, relieve the fuel rail pressure by pressing the Schrader valve in.
Figure 3

Using a flathead screwdriver and a rag, relieve the fuel rail pressure by pressing the Schrader valve in.

Using a fuel line release tool (5/16) (red arrows), release the fuel line (green arrow).
Figure 4

Using a fuel line release tool (5/16) (red arrows), release the fuel line (green arrow). Press the tool in toward the line to release the locks. Then slide the line off the fuel rail.

Remove the two 10mm fuel rail fasteners (red arrows).
Figure 5

Remove the two 10mm fuel rail fasteners (red arrows).

Then pull the fuel rail straight up and out of the intake manifold.
Figure 6

Then pull the fuel rail straight up and out of the intake manifold. Be careful not to damage a fuel injector when removing it. If the O-rings are stuck, you can lightly lever the fuel rail up using a flathead screwdriver. I like to lever between the edge of the valve cover and the fuel rail. Spray lubricant around the O-rings. This will make removing them much easier. If there is dirt in this area, remove it before spraying the lubricant.

Flip the fuel rail over and disconnect the electrical connectors (red arrows).
Figure 7

Flip the fuel rail over and disconnect the electrical connectors (red arrows). Press the release wire and pull them straight off (inset).

With the fuel rail on a bench, remove the three T25 Torx fasteners (green arrows).
Figure 8

With the fuel rail on a bench, remove the three T25 Torx fasteners (green arrows).

Then, remove the fuel injector locking plate (red arrow) from the fuel rail.
Figure 9

Then, remove the fuel injector locking plate (red arrow) from the fuel rail. At times it will stick. If yours is giving you trouble, gently lever in the area of the fuel injectors (green arrow) to free the plate. If the plate bends or is damaged, replace it.

To remove the individual fuel injectors, pull the fuel injector straight out of the fuel rail.
Figure 10

To remove the individual fuel injectors, pull the fuel injector straight out of the fuel rail.

To remove the fuel pressure regulator, pull the regulator (red arrow) straight out of the fuel rail.
Figure 11

To remove the fuel pressure regulator, pull the regulator (red arrow) straight out of the fuel rail.

When reinstalling the fuel injectors, replace the sealing O-rings and be sure that the locking plate is properly seated in the injector groove (green arrow).
Figure 12

When reinstalling the fuel injectors, replace the sealing O-rings and be sure that the locking plate is properly seated in the injector groove (green arrow). Press the fuel rail with the injectors into the intake manifold until fully seated. Then install the fuel rail fasteners and tighten them. Reassemble the remaining items and check that there are no fuel leaks.

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