2004 v70 Non-Turbo - Fuel Rail Stuck

[jasmith86]

I can't separate my fuel rail from the intake manifold.

First time posting here. I am working on my '04 non-turbo v70. Long story short I am trying to remove the intake manifold to get to PCV system. I am following these instructions: https://www.matthewsvolvosite.com/forums ... p?p=373460. Also, I attached a pic with where I am at now.

My problem is that I cannot remove the fuel rail. In the picture below I removed the two hex bolts (ORANGE), disconnected the injector plugs (YELLOW), de-pressurized the fuel line, and disconnected the pressure sensor from the rail.

I have been fighting with the 'quick disconnect' where the fuel line hooks into the rail (RED) for about an hour, without getting anywhere. I have made sure to be gentle as I don't want to bugger up the injectors. I push the two green 'buttons' on the quick disconnect and have tried to pull out the fuel line as well as wiggle the rail, but no luck. I have verified that all bolts, etc. have been removed -- the only things connecting the fuel rail to anything are the injectors themselves and the fuel line. The injectors move slightly, but the fuel line is not budging.

Any help would be greatly appreciated!!!!

Update: I've had enough fun fighting with this thing tonight. Back to it in the morning!

[oragex]

The green clip has two tabs. The one we see in the picture, and a second one underneath. Try pushing with a flat screwdriver from underneath while depressing on the other side with another flat screw driver. The tab goes a bit inside then stays here: the clip is in the release position then. It's not that hard because that fuel it doesn't get seized. Then it takes a little persuasion with the injectors seals which keep the rail in place. A screw driver as a lever to pull on the rail a little at a time on each side works fine. When putting back the rail, a little Vaseline on the injectors seals helps sliding it back in place.

Edit. An universal joint adapter is almost a must when releasing the upper left corner bolt of the manifold. If not, the thermostat housing (along with the power steering pump) must be removed - another headache. A manifold gasket is also almost surely needed, good to have in hand.
http://www.ebay.com/itm/400782970823?_t ... EBIDX%3AIT

[jasmith86]

The green clip has two tabs. The one we see in the picture, and a second one underneath. Try pushing with a flat screwdriver from underneath while depressing on the other side with another flat screw driver. The tab goes a bit inside then stays here: the clip is in the release position then. It's not that hard because that fuel it doesn't get seized. Then it takes a little persuasion with the injectors seals which keep the rail in place. A screw driver as a lever to pull on the rail a little at a time on each side works fine. When putting back the rail, a little Vaseline on the injectors seals helps sliding it back in place.

Edit. An universal joint adapter is almost a must when releasing the upper left corner bolt of the manifold. If not, the thermostat housing (along with the power steering pump) must be removed - another headache. A manifold gasket is also almost surely needed, good to have in hand.
http://www.ebay.com/itm/400782970823?_t ... EBIDX%3AIT

Thanks oragex.

So I got the two green clips pushed in, but I'm still not having any luck... Here's a pic of how it is right now:

Do I depress the tabs in towards the fuel rail, rather than towards the engine (like in the above picture)?
I've tried and the fuel line just ain't budging.

[oragex]

Is the tab underneath pushed in the same? If so the line should be free to remove (the black plastic part stays with the rail). Don't force on the line itself either direction (someone had bad luck with gas leaking afterwards). Once the green clip is uncliped the line should slide easily out. Unless the seals on the injectors still keep the rail in place. The rail has to move about 3/8" until these seals let go.

[jasmith86]

Is the tab underneath pushed in the same? If so the line should be free to remove (the black plastic part stays with the rail). Don't force on the line itself either direction (someone had bad luck with gas leaking afterwards). Once the green clip is uncliped the line should slide easily out. Unless the seals on the injectors still keep the rail in place. The rail has to move about 3/8" until these seals let go.

Yep, bottom tab pushed in just like on the top. It doesn't feel like it has released anything. I did notice that this green ring (shown below) is loose. I have tried clicking it back into the disconnect but it doesn't seem to go. In this video @ 4:14 https://youtu.be/yaHFgfLWvCI I don't see the green ring, so perhaps it doesn't matter.

I'm considering getting a fuel line disconnect tool (http://m.advanceautoparts.com/mt/shop.a ... t_redirect) and seeing if I can spread the green part of the inside of the disconnect enough to release the fuel line.

[oragex]

When the two green tabs in the black plastic piece stay depressed, there is nothing to keep the fuel line in place, it slides in or out with a finger push. It's not the line that will move out because it's a rather rigid piece of pipe, rather the fuel rail will slide off the line once freed from the injectors.

I too have the green ring piece loose - it sits somewhere down the fuel line, not sure what is used for perhaps it's an extra safety clip. I did not put it back because it did not stay in place.