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95 960 injector ends/seals S90-V90

I'm presently in the middle of replacing my intake manifold gasket, I have the manifold back together, however I still have the injectors to put back in.

I have noticed that on the injector ends that point into the manifold/engine, there is a round plastic 'cap' which appears to clip on to the injector end. I don't really know what these are for, as they leave a large hole on the injector end, however I've noticed that this cap on cylinder 6 injector has cracked.

Are these necessary to retain on the car? Are they supplied as a replacement with the lower O seal? I should renew all the O seals while they are out. I just don't know whether to worry about this plastic part or not.

Thanks








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    95 960 injector ends/seals S90-V90

    There is an injector seal kit which should contain these little plastic caps. It's made by Bosch, and can be bought from a Volvo dealer; Volvo P/N: 1346393.

    I have replaced these before, but I didn't buy the kits fro Volvo, but from diyautoparts.com. You can go to that site and plug in year/make/model info, then look in Engine->Fuel Injection, and find the seal kit. They have a nice picture of the parts. I remember the little yellow caps, but I couldn't remember if they were included in the kit or not. It looks like they are.

    I also seem to recall that it contains an extra part or two per kit. I don't think the grey plastic ring applies to the Volvo injector configuration.

    You'll need one kit per injector @ ~$6 ea.

    You'll also one 'pancake washer per injector. These go between the upper end of the injector and the c-bore in the fuel rail. You MUST have these or you'll have leaks and have to take the thing off again. Another ~$1.50 ea.

    You might as well also get the sealing rings that go in the c-bores on the intake manif. There are different versions show w/ & w/out EGR.

    You should also get the sealing o-rings for the fuel pressure pipes at the fuel rail. I think there are just two of these; one for supply & one for return.







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