I am replacing the EGR system on my 850, and thanks to lots of good info from forum members, I am almost finished with it. The one problem I have is that there is some flat rubber washers that fell out of some where while I was taking it apart. The fuel rail does not have a nut to remove the fuel line as in the posted pictures, so I had to remove the fuel rail and gently move it out of the way while removing the intake. Do these washers go up inside the rail, and if so how to I keep them from falling out again when I snap the rail back down on the injectors? I was lucky enough to be able to find all five that fell out.

 

I assume you are talking about the O-Rings that go on the injectors themselves. If they look like washers you really need to change them. Most of the Advance Auto, O'Reilly, etc auto parts stores have them. They should roll up on the injectors into a groove just above the plastic cap. I've not had the injectors out of any of my Volvos and I've seen conflicting pictures as to whether there are two O-Rings per injector or just one. The last fuel rail I pulled was on my daughter's Porsche and it only had one O-Ring, they were Bosch injectors as well.

Check the condition of the caps on the end of the injectors, if they are broken get the full kits and replace the caps as well. If you wind up with the blue Beck/Arnely replacements it takes a lot of pressure to get them snapped back on. They need to click twice to get seated.

...Lee

 

On some of the older cars there is washer/seal looking things around the injectors where they go into the intake. Yes they are needed or I belive the injectors will leak.

 

No, these are not the O rings that are on the injectors, these are pretty much flat, looks like a small grommet, the O rings are still on the injectors. I do not know where these came from, as I was unbolting the intake, I noticed them laying on top of it. I found a total of five, so I am assuming that they came from there. I did pull and inspect the injectors, maybe they came from underneath the them where they push into the intake?

 

If there is like circle cutouts around where the injectors go in then they should go there.
You would set them on the hole then install the fuel rail through the seals.

 

The cicle cutouts on the intake have a blue washer in those, the top of the injector has the O ring, but no place for the flat washer to sit, and the hole in the washer is too small to go over it. The only place I can figure is it goes up into the fuel rail first, then the injector is pushed in, then with all of the injectors in, the whole assembly is pushed onto the intake. The hole for the injector in the fuel rail is a smooth bore, so unless the washer is slightly oversized it would not stay up there. Since I'm working upside down, It's a real challenge to put the washers up there and see if they are flat in the top of the bore. Dropping one is not an option, as I think I was extremly lucky in finding all five the first time! I will see if the washer will fit up there in the morning.

 

I just noticed that I posted that I'm changing the EGR (exhaust gas recirculation) system, but I am actually changing the PCV (positive crankcase ventilation) system, doesn't change what info I need, but my bad!

 

Can you post a pic of them?

 

Here is the picture (if it works). I am begining to believe that these are not factory, but were added by a previous mechanic. I cannot find a exploded diagram of whats supposed to be there, so I can only guess. It looks too much like someone took a rubber grommet and used it as a gasket, maybe the old O rings were not sealing good and they added these.

 

Here is a side view

 

It looks like an injector o-ring to me.
Maybe someone replaced them at one time and just dropped the old ones down.

 

OK the side view makes it a little better.
I believe they go between the top of the injector and the fuel rail.
So you would have to remove the injector from the fuel rail and slide it in there and reinstall the injector.

 

It's kinda weird that it has a groove around the outside, just like a grommet.

 

Yes I know not sure why they do it either.

 

Got everything back together, but left out the grommet looking washers. Looked on several parts websites and did not see them listed. It did not make sense that an engineer would design something like that. One of the injector caps was broken, so I went down to O'reillys and bought the O ring kit with the replacement cap. The new O rings were slightly larger and fit better on the injectors, and all of the caps were brittle, so I went ahead and replaced all of them. No leaks! I think someone previously installed the grommets to stop the leaks that the old O rings were causing. Replacing the PCV system solved another issue that I thought was unrelated, For three years the car had a hot motor winding smell if the heat/AC fan was left on low. I would just leave it on manual medium to high speed, and the smell would go away. I figured it was either the blower motor or the speed control causing this, but it does not do it any more now. Go figure!

 

Glad all is working good now.

 

hey, i got the same car basically. and yes they go on the fuel injectors. they sit in on the intake manifold there. they should be blue. and try putting the injectors on the rail first and then pushing them into the intake. if anyone knows where i can order that part let me know. i lost one. and i kinda did some back yard engineering with 3 medium size o rings and a large one out of the kit you get from pep boys. so if anyone can post a link. i like to buy 5 new ones soon

 

What he has in the picture with the slit around the circumference is a classic rubber grommet as used to protect wire going through a bulkhead or panel. The groove in it is what holds it in place when pushed into a hole. There is a "flap" on each side holding it in place to protect wire running through the center of the grommet and keeping it from pulling or pushing out of place.

All "O" rings I've ever seen are solid. They need to be solid to seal against pressure or you'd just have flaps with a channel to cause a leak. Pretty sure IF, IF they were used in the fuel system they were not fuel resistant quality nor the proper part.

The Volvo injectors will have an "O" ring at the top and bottom and using Vaseline to lightly lube the rubber will assist in getting the ring on the injector and seating it properly into the rail and intake.