I pulled the spewing fuel rail off of the 960 yesterday and posted some pictures after the tear down.


I apologize for the fuzzy picture, but you can see what causes these rails to leak out the end seal. There is an "O" ring that degrades and no provision for a way to simply replace it except for installing a new rail.

After cleaning and deburring the end of the rail that holds the plug, I took a 1/2" copper sweat cap and swagged it into a bell shape (using small sockets and a vise) that just pressed into the rail with the big end inwards. I then fitted the plug with J-B Weld and let it sit over night. After re-installation in the vehicle, I tested the system by starting the car and had no leaks. At least in the preliminary test the plug + J-B Weld is going to work.




These photos were taken with the car running.

I would caution you that if you feel uncomfortable with this type of repair, don't do it! I personally do not feel that it is anymore dangerous than the system that Volvo designed, considering the frequency of failure.

Regards,