2009 XC90 3.2 Fuel Injectors

woodg · Post by **woodg** » 31 Jul 2018, 19:17

My wifes XC90 has thrown a code that indicates a bad #6 Injector. I'm having a dickens of a time figuring out how to get the fuel rail out. I've got the bolts out and it's moving but not coming free. I can see where the fuel line comes in, but not how to get to it to disconnect it. I'm also not finding anything on internet searches.

Any help would be appreciated.

Post by **ggleavitt** » 01 Aug 2018, 12:03

Had to check the repair procedure, release pressure by removing fuel pump fuse (#8 in engine compartment, start car-let die, try to start for another 5 secs), then the 3 bolts plus the fuel connector comes off (https://workshop-manuals.com/volvo/xc90 ... nd_repair/), and you "should" be able to pull the rail and the injectors out in one piece. It should come out with some gentle rocking and consistent upward pressure.

I had a heck of a time getting the injectors and the rail off my V8 when I did valve cover gaskets, to the degree that I broke some pintle caps and plastic parts on the injectors and eventually had to source another set (old set was rebuilt, kit took a few weeks to arrive). For the V8 there is a side-note to "spray with universal oil or the like around the injector valve locations on the cylinder head", which of course I did not follow.

You could try to put a little something to lubricate the base of the injector, let it get around the o-ring, then try pulling again.

Edit- 8/1/18-add note about releasing fuel pressure

woodg · Post by **woodg** » 01 Aug 2018, 13:26

Thanks. If it were only that simple. The lock shown in the diagram that you included the link to, is not there on the 3.2L. That is what is throwing me for a loop. Also the fuel line that attaches to the rail appears to be one continuous piece as far back from that rail as I can trace it. I just don't see any connector for the fuel line to the rail.

Also for what it's worth, this is my 6th Volvo and I do all my own work. A few years ago I replaced the flywheel, clutch, Alternator, VVT hub, and every seal and belt that I could get to while I had the engine out of my S-60 T5.

woodg · Post by **woodg** » 01 Aug 2018, 13:56

Good news.... It's off.
There is no lock, but it takes more force than I would normally be comfortable applying. I actually had to pry it off with a screwdriver and the fuel line is simply a slip fit. No locking mechanism at all.

Post by **ggleavitt** » 02 Aug 2018, 07:52

Thanks for the update, VIDA shows the pipe going straight into the rail, the other site noted a lock. Seemed intuitive that there would be a lock of some sort, guess not. Now we know.

Post by **oragex** » 02 Aug 2018, 10:51

I use a pry bar too to pull the injectors from there: the o-rings are quite tight and prevent the injector to slide easily out of its intake hole

Remember to always clean perfectly the o-rings, their seat on the injector as well as the hole in the intake, as lube everything with a thin film of Vaseline before inserting (Vaseline is fine, the o-rings are designed for gasoline which is a petroleum product just like the Vaseline is)

Post by **ggleavitt** » 02 Aug 2018, 12:46

Not to belabour the point, but if I'm pulling the rail and injectors and I don't think I'll be back in there again, if it's my personal car I do new O-rings across the board. PN 30731807 (kit with 2 o-rings), 1 per injector. For what it's worth...

Edit- o-ring PN is kit