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Smoke test - leaking injector

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Vuym
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Post by Vuym »

I did a smoke test on my 03 S60R because my boost was a bit inconsistent. Noticed that it all seems to becoming out of one injector - is this likely a failed o-ring? Any other suggestions?

Thanks!
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Vuym
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Post by Vuym »

Not the greatest video but hopefully shows what I’m trying to describe
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jonesg
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Post by jonesg »

spray with brake cleaner whilst its idling.
but its leaking.
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DavidE7
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Post by DavidE7 »

The P2 fuel injector o-rings used by Volvo are somewhat of a standard size and you should be able to get them at any auto parts store. Replace all 5 of the lower o-rings if one is bad. My 200,000 mile Volvos ran smoother after sending the injectors out for ultrasonic cleaning and balance testing. The injector shop also replaced all the o-rings, filters, and plastic caps and made them work and look like new. This YouTube video looks good for the injector removal procedure:
You don't need to remove the injectors from the fuel rail to replace the 5 o-rings sealing the injectors to the intake manifold.
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br0dy519
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Post by br0dy519 »

Don't forget to grab some replacement pintle caps while you're in there. Good to get an o-ring and pintle cap kit. Easy job.
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BlackBart
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Post by BlackBart »

DavidE7 wrote: 26 May 2026, 20:39 My 200,000 mile Volvos ran smoother after sending the injectors out for ultrasonic cleaning and balance testing.
Where did you send your injectors?
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ToyoToyo
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Post by ToyoToyo »

Definitely replace all the lower o-rings while you're in there, they're cheap and it's not worth going back in just to do the others a few months later.
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Vuym
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Post by Vuym »

So o ring was definitely busted but not sure how to remove this transparent washer-like thing so that I can replace the rubber o ring. Is it just brute force with a flathead?
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Vuym
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Post by Vuym »

Nvm it stretches over it!
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abscate
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Post by abscate »

Brute force with a pick on the oring! Shot of silicone spray helps too
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