Genuine Volvo 960 Fuel Injector

Volvo 960 Fuel Injector Parts and Q&A

• Injector
  9454555
  Q: How to remove and install fuel injectors on Volvo 960?

  A:

  To remove & install fuel injectors for 2.3L 4-Cylinders & 2.8L 6-Cylinders, release fuel system pressure, disconnect the negative battery cable, and disconnect fuel lines, electrical connectors, and vacuum hoses from the injection manifold & pressure regulator. Unbolt the pressure regulator, remove the injector cover plate if present and remove the fuel injection manifold with the injectors as a single unit. Secure the manifold in a holding fixture to remove the fuel injectors. For the installation, check the fuel injector O-rings and replace them if necessary, coat them with petroleum jelly, and install the injectors in the manifold. Reconnect the manifold and injectors, tighten the retaining bolts and connect the pressure regulator, vacuum hose, fuel lines, and electrical connectors before connecting the negative battery cable and starting the vehicle to check for leaks. For 2.9L 6-Cylinder engine, refer to the same steps, be sure to release fuel pressure, disconnect battery, remove fuel rail protective cover and lines. Label and remove electrical connectors then remove the fuel rail assembly and injectors. Lubricate O-rings on the new injectors, install them into the fuel rail and reassemble the components ensuring the O-rings are properly seated and checking for leaks after starting the vehicle. For 2.3L and 2.4L 5-Cylinder engines, you will need to remove the throttle pulley cover; remove fuel pressure, disconnect battery; remove parts such as upper air charge pipe, fuel rail cover. Disconnect the vacuum hose, lift the fuel rail using injectors, and replace the injectors as needed and make sure to keep the rubber dampers in place. Lubricate new O-rings and install injectors, and reassemble fuel rail and other components, reconnect the battery and search for leaks. To check the operation of the injector, listen to the click on a mechanic's stethoscope or screwdriver, if all injectors click, but problems still exist, then check Fuel Pump pressure and carry out a drop test of cylinders. For non-clicking injectors, use a "noid" light to test the injector driver circuit, if the light flashes but the injector does not click, then replace the injector. If the light does not flash, test the circuit for faults, making sure the resistance is less than 5.0 ohms, and replace the ECM, if necessary.