Well, I feel your pain but sometimes that's the way it is. .005" shouldn't matter but looks like it does. Also, the ones you have may be less dense, different grade rubber, who knows? Also, I use petroleum jelly for O rings...

 

I called and ordered the o-rings from the local Volvo dealership and I thought they said something like $7 per cylinder. I got home from work and looked at my bank account and the charges for the o-rings came to nearly $90. I called them back and said to cancel my order. I'm going to sell this car to the junk yard and buy something american. Any company that would try and charge me $90 for 12 o-rings is not a company I will do business with any more. I liked this car but not enough to let a company take advantage of me that bad.

 

I think that way often. But in all honesty pretty much all car brands charge some ridiculously high prices for certain parts, American cars are no exception. Volvo maintenance items generally are on the lower side of the price range; in this case I agree that it does seem high...

 

 

There's plenty of online sources for genuine Volvo and quality OEM parts. Not sure about parts not fitting for any reason other than you ordered the wrong parts for your engine. Best to double check VIN and build plates / stickers to know which exact engine you have.

You can try FCP Euro, IPD USA, EEuroparts and find a 4-set of injector seals go for about $5 for the older KJET style injectors. You didn't mention what engine or model year you are trying to match up. If you need Genuine Volvo, try Tascaparts.com (best prices for a dealer web store that I know of)

 

Well, OK. But just for argument sake, I have had many, many, many Volvos pass through my hands, but just a couple of 960... I don't care for them and I'd never own one for personal use. If you had stuck to the Red Block, 240, 740, 0r a 940, your experience would have been very different.

The 960, a luxo boat intended to go against other lux brands is full of misses the other RWD Volvos don't share: the 960 has a suspension that is way too complicated, the head is a bad Porsche design with a nasty record of belt related failures, the transmission is an electronic headache, even the keys, "high security" that they are, are bad, as is the HVAC system that is practically unfixable once it goes bad; other than that the 960 is a nice car. You just chose the wrong Volvo model as a "poor man's" car.

 

It's all relative to one's experience and perspective. I too have owned and serviced many Volvos (247, 850, 740, 940), along with too many other brands, and now own and service a 97' 960. Having rebuild the entire engine, I now have a reliable, easy to maintain, smooth driving vehicle with 210,000 miles, and counting. Comparatively, my experience with owning and working on American cars falls far short of the pleasure of maintaining this beauty. Oh yeah... I bought a complete set of six brand new injectors--O-rings included--a year ago, for a total of $100 bucks, that have never leaked.