'99 S-80 T6 Fuel leak at injector rail

SimLyons · Post by **SimLyons** » 21 Dec 2013, 23:43

This problem is so dangerous that I parked the car and am waiting for parts.

I had (have) a fuel leak at the point on the rail where the fuel supply line connects. I had jst replaced all the injector seals while doing the timing belt, serpentine belt and all the other odd parts. When I reassembled it and went for a test drive I began smelling raw fuel. I got home, popped the hood and was surprised and the strength of the fuel odor.

I started it back up and saw fuel dripping in the area of the fuel line. I removed the cover over the injector connecion and saw fuel dripping from the connector. I replace the seal (green oring) and put it back together. Still leaked, so I removed the fuel line, cleaned out the port and reconnected. Still leaked. So I mixed up some epoxy supposedly, gas resistant, and put it all together again. It took 10 minutes to leak again.

Now I have a new rail on order and a new connecting line in my garage. I hope this will do it. Does anyone else out there have experience like this? I've had a lot of Volvos (740, 760, V70s, etc) and never a leak like this. I'd appreciate any advice.

MyS40T4 · Post by **MyS40T4** » 22 Dec 2013, 03:41

Hello,

It's definitely the point where the fuel rail connects that is leaking? The reason I ask, is that I replaced the injector o-rings on my S80 and had leaks near the join. When I ran my fingers along the fuel rail, it became apparent that the leak was actually from the injectors as well. The o-rings that I'd bought (supposedly for this car) were marginally too small. I went to a specialist seal supplier with the injectors and rail and asked for some viton o-rings to fit snuggly. The size the guy supplied after measuring were spot on and not a metric size from memory...

Cheers,

Chris

SimLyons · Post by **SimLyons** » 23 Dec 2013, 23:54

Thanks for that, Chris. I did locate a leak adjacent to the fuel line, at #5 injector. I replaced that pair of seals with another set of new. It stopped right away but I could see the fuel running down the hose, apparently from the connection at the rail. I'll know more tomorrow as I intend tostrip it down to basic essential and run it. Then I can get my mirror back there and confirm it.

Either way, another set of new seals and the "new" rail are going in, along with the new fuel hose/connector.

Have a good Christmas!