1996 Volvo 960 Fuel Rail

[onevolvoowner]

I had to use the S90 1997-1998 fuel rail. plus also used the bolts with it.

[RickHaleParker]

The only difference between a '97 960 and a '97 S90 is the badge. My '97 S90 is titled as a 960.

[Volvo2009]

So you mean same fuel rail for 96 960 & 97 S90 models fit for both cars?. I would appreciate if you could post the correct Part number for it.

[RickHaleParker]

Your '96 960 fuel rail is Volvo part number 1271738 or 9179348.

You can use either one but be aware there is different mounding hardware for each of the two.

There are some other Fuel rails that may or may not work with your '96. They are for cars with non-return fuel system. I don't have one on hand so I cannot check to see if the second delivery port is blocked off and un-blockable or not there at all.
The part numbers are 1270346, 9189120.

The quick and easy way to tell a non-return fuel rail from a return fuel rail is look on the back side where the injectors go in. The return version has two delivery ports the non-return fuel only has one ... maybe two with the second one blocked off.

[Volvo2009]

Thanks Rick
I was hoping there is an aftermarket part for my car. From your reply, I gather there is none.
Anyway, I will forward your comment to my mechanic and hopefully, we will be able to figure it out. This car has only 150K miles and runs like new. I was planning to drive it a couple of more years then get a hybrid car - though I am still not sold on rechargeable batteries.

All the best
Levi

[Volvo2009]

Rick,
Here is what my mechanic wrote on his recommended note:

"Confirmed fuel smell under the hood around the fuel rail & injections. The end of the fuel rail is seeping fuel around the test port.
Recommend replacing the fuel rail, both the fuel feed and the return hose from the pressure regulator to the hard line back to the fuel tank. The feed & return lines are special hoses, will also require all new injector o-rings."

Is the anything can be done - within reasonable price to save this car?

[RickHaleParker]

Is the anything can be done - within reasonable price to save this car?

If it was in front of me, it would of been done a long time ago, new rail or not.

The end of the fuel rail is seeping fuel around the test port.

That would be the Schrader Valve on the back side near the firewall. Which is for checking the fuel pressure. You don't need it for the car to run. The Schrader Valve could be cut off and a Aluminum cap JB Welded over the end would stop the leak. A new Schrader Valve could be fitted to the cap.

Recommend replacing the fuel rail, both the fuel feed and the return hose from the pressure regulator to the hard line back to the fuel tank.

Are they leaking?

The feed & return lines are special hoses

If one can get the ends off, one can make new hoses.

Is the anything can be done - within reasonable price to save this car?

will also require all new injector o-rings

Cheap and easy.

If you cannot do the work yourself. At least take it to another mechanic. I am getting the impression the one you are using is what we call a part changer, meaning he does not have any fabrication skills. There are lots of other mechanics that can do more then just change parts.

[June]

Perhaps the rail off of a 98 S90 or a 99 S80 2.9 might be of the updated design and possibly fit? Go online and throughout the country must be specialty Volvo salvage yards they for sure will either have a 960 good rail, or know what will interchange. For example; Lincoln Land in Clearwater, Florida who specializes in only Lincoln parts and knows what will interchange.

Also check OEM Parts Direct they had a replacement seatback cover and obtained the bottom from Volvo in Sweden for my 2004 S80. My dealer said it was discontinued. My dealer has my car now and I should get my car back Monday with the new genuine Volvo leather installed. The link to OEM Parts direct disappeared off of MVS, but they must be on the web. They are a Volvo dealer in Pennsylvania but seem to have resources my dealer doesn't have like maybe a large warehouse or something.

I know the frustration too well to be told a part is not available as I just went through it with my driver seat. Stick with it and somewhere is either a new old stock or a used one with your name on it. June

[Volvo2009]

Rick,
Thanks for the replay. I am a handyman, but not for this job. Meanwhile, I was referred to Mega Euro Auto Dismantlers in S. CA (909-803-5700) who said they do have the part ($150). I will have my mechanic-friend to follow up on it and go ahead and have it fixed then sell.

June
Thanks for the reply. I am not sure the fuel rail for the car you had posted fit my car - otherwise, my guy could find it pretty easy. I certainly will follow up on your tip and post the result here.
Thanks
Levi

[vp965]

A used fuel rail from a So Cal salvage yard chain (LKQ) costs about $15. A 30-day warranty would cost you another $5 or so. They have a bunch of 960/S/V90 cars in stock on their yards. It takes about 5 min work, a few basic tools (T25 and Phillips #2 screwrivers, 10mm socket, ratchet and extension and cutting pliers or a knife to cut the fuel lines) to get the fuel rail out. Actually, I believe S/V90 will have a slightly different fuel rail design, but they're likely interchangeable since it's the same engine, same fuel line fittings... In any case, easier to find a 96/97 960 than a S/V90. Given the age of the car and the quantities in which they were produced, it's no surprise that Volvo is cutting costs on stopping to stock many parts for these cars.
Besides the self-serve option there's a number of companies out there that specialize on old stock and used parts for these cars -- I've seen quite a few referenced on this forum and on Brickboard. Good luck.