2008 S60 2.5t fuel rail removal question

Sagan · Post by **Sagan** » 28 Apr 2014, 15:09

Hi folks. I'm trying to remove my intake manifold, but need to get the fuel rail off first. Any idea how to separate the gas line? I got the screwed on clip off, but I can't figure out how to disengage it from the rail.

: ImageUploadedByTapatalk1398719233.764874.jpg (279.23 KiB) Viewed 5973 times

Clip

: ImageUploadedByTapatalk1398719328.249455.jpg (135.58 KiB) Viewed 5973 times

Line

Sagan · Post by **Sagan** » 28 Apr 2014, 17:14

Never mind. Apparently you just pull hard after you get the clip off.

johnljoseph · Post by **johnljoseph** » 11 Jun 2016, 07:21

Wow... it took a long time to find this answer. I am in the same boat. I have a 2005 Volvo S80 2.5T ( B5254T2 engine). I have a similar clip. I read that it is one of several clips used and was new in 2005. (Don't know if that's right.) I spend an hour trying to get the fuel line out. I guess I'll have to just find a way to yank on it harder. I saw in a parts listing that there is an o-ring here as well which I neglected to have on hand.... trip to the dealer, I guess.... Thank you for your post. It will save me from doing the wrong thing for another hour.

Here is a link to the part in question, should you be having the same problem...

https://www.ipdusa.com/products/7754/11 ... er-fitting

Post by **abscate** » 15 Jun 2016, 18:52

You need a fuel line release tool to release the fuel line, or fabricate something similar.

Pulling harder is not the answer.

Post by **vtl** » 16 Jun 2016, 06:12

abscate wrote:You need a fuel line release tool to release the fuel line, or fabricate something similar.

I needed one for 2002, but not for 2005.

Post by **abscate** » 17 Jun 2016, 18:38

It turns out there were different styles of connectors used in 2005, so, as they say, YMMV

goldxc70 · Post by **goldxc70** » 07 Apr 2017, 14:56

With the new style quick connector, where does the o-ring go? Does it just sit on the shoulder of the fuel line? Or does it go inside the fitting? I'm changing for the old style to the new style as mine appears to be falling apart.

Post by **mrbrian200** » 07 Apr 2017, 15:58

O ring goes into the hole in the fuel rail first. The larger plastic fitting sits behind that and is locked in place by the flat steel bracket that's held in place by several screws (locking it to the rail same way as this bracket holds the injectors). Mind the orientation of this part so that the hole for the set screw/lock is 'up' when the rail is reinstalled on the engine. The smaller plastic piece/screw locks the steel fuel line to the larger plastic bit so that can't pull out and is installed (slides into the larger plastic fitting over the fuel line) after the assembly has been placed physically back onto the engine.

A dab of clean engine oil or petroleum jelly on the o-ring/fuel line will ease reinstallation (also recommended on the injector O-rings and their holes on the intake manifold).

Older ones were a different style quick connect fitting which could be a PITA and required a special tool to release.

goldxc70 · Post by **goldxc70** » 08 Apr 2017, 12:23

Thanks. That information made for a easier job. I replaced the old style plastic quick connect (also with an o-ring in the rail) with the new style plastic quick connect (with the screw). Having completed the job, I doubt that it was a problem but time will tell. Here's a picture from the IPD site: https://www.ipdusa.com/uploads/images_p ... nt/742.jpg

Post by **vtl** » 08 Apr 2017, 18:10

Interesting. My 05 does not have O-ring.