Vacuum Leak, Please Help

[JBVolvo]

I am confused now. Are you saying that I don't have a problem at injector 5 location? Or are you saying that I need something other than O-rings?

keep in mind my info is coming from a NonTurbo 96 850.

1 - theres an oring on top of the injector where it sits in the fuel rail.

2 - theres a rubber spacer that sits above the injector in the fuel rail

3 - theres an oring on the bottom of the injector (same type as #1) where it sits in the cyllinder.

4 - theres a fat rubber seal that sits in between the two orings thats visible just looking at where they enter the intake.

If you have a vacuum leak at one of the injectors, like it sounds like you do...I'd guess its at the fat rubber donut seen in the picture below at the tip of my fingers (not the tattered oring)

Also seen here in FCP pix:

[I hate haters]

theres an oring on top of the injector where it sits in the fuel rail.

theres a rubber spacer that sits above the injector in the fuel rail

theres an oring on the bottom of the injector where it sits in the intake.

and theres a fat rubber seal that sits in between the two orings thats visible just looking at where they enter the intake.

if you have a vacuum leak at one of the injectors, like it sounds like you do...I'd guess its at the fat rubber donut seen in the picture below at the tip of my fingers (not the tattered oring)

Also seen here in FCP pix:

I didn't realize that those hold pressure/vacuum what do the o-rings seal then? Only fuel? I read somewhere that those seals are there to keep the dirt out. The one you are showing from FCP is the upper at rail seal for a non turbo model the one you have. I have a T5 and my injectors look different from yours.

I will pull the rail off tonight and look at the injectors.

[JBVolvo]

I didn't realize that those hold pressure/vacuum what do the o-rings seal then? Only fuel? I read somewhere that those seals are there to keep the dirt out. I will pull the rail off tonight and look at the injectors.

I edited my above post a little bit...re-read it again.

Also -

When you remove the fuel rail you need to be careful of a few things.

you want to remove the rail with all the injectors installed in it.

I physically hold each injector in my hand to pull it gently straight out with the rail - one injector at a time.

If you pull just the rail, you may end up leaving an injector in the intake, and the upper seal will probably go flying (goodluck finding it).

EDIT: From what I can tell, the two alike orings (top and bottom of the injector) seal fuel from leaking internally (in the intake) and externally (from the rail). But the donut seal I showed is a vacuum seal. My guess is you didnt fully seat one of those seals in the intake (which you may be able to see without even pulling the rail and can use a screw driver or something similar to push it completely into its seat)...or you nicked it while you had the rail removed.

[I hate haters]

Problem solved.

Yesterday I was searching for possible solutions and bumped into this:

http://volvospeed.com/vs_forum/lofiversion...php/t39183.html

It was exactly what happened to me. The metal plate on the very right bolt on the manifold that holds the PCV tubing in place was between the manfold and the gasket. Obviously that created quite a large gap. When I was installing the manifold I dropped one bolt and it fell right in between engine block and PCV canister. My magnetic pick up tool wouldn't go in that small of a gap, so I had to pull the manifold off undo one bolt on the canister to pry it off slightly and get the gap to open more for the pick up tool. After I did that I probably forgot about that plate and when installing the manifold I bumped it next to the gasket. So I removed the plate and put it where it supposed to go and it took care of the problem. I took some pics and will add them later. Vacuum now is at 20-22 inHg.

While I was there I also replaced the lower injector O-rings. I went to NAPA and got several sets of O-rings for a '95 Mustang GT.

JBVolvo, I must say that O-rings on my car definitely provide an air tight seal. My injectors are different from what you have and I also don't have those flat rubber washer looking seals (donut seals) that some people have apparently. Those do not seal anything, they are there to keep the dirt out. Also, I have a locking feature on my fuel rail that holds the tops of the injectors attached to the rail so in order to leave an injector in the manifold you would either have to break the injector or bend the metal locking plate. By the way I tried removing injectors from the rail but they were in there very tight and decided to leave it alone.

Thanks for your help everybody.

[JBVolvo]

Problem solved.

Yesterday I was searching for possible solutions and bumped into this:

http://volvospeed.com/vs_forum/lofiversion...php/t39183.html

It was exactly what happened to me. The metal plate on the very right bolt on the manifold that holds the PCV tubing in place was between the manfold and the gasket. Obviously that created quite a large gap. When I was installing the manifold I dropped one bolt and it fell right in between engine block and PCV canister. My magnetic pick up tool wouldn't go in that small of a gap, so I had to pull the manifold off undo one bolt on the canister to pry it off slightly and get the gap to open more for the pick up tool. After I did that I probably forgot about that plate and when installing the manifold I bumped it next to the gasket. So I removed the plate and put it where it supposed to go and it took care of the problem. I took some pics and will add them later. Vacuum now is at 20-22 inHg.

While I was there I also replaced the lower injector O-rings. I went to NAPA and got several sets of O-rings for a '95 Mustang GT.

JBVolvo, I must say that O-rings on my car definitely provide an air tight seal. My injectors are different from what you have and I also don't have those flat rubber washer looking seals (donut seals) that some people have apparently. Those do not seal anything, they are there to keep the dirt out. Also, I have a locking feature on my fuel rail that holds the tops of the injectors attached to the rail so in order to leave an injector in the manifold you would either have to break the injector or bend the metal locking plate. By the way I tried removing injectors from the rail but they were in there very tight and decided to leave it alone.

Thanks for your help everybody.

the "donut seals" are a vacuum seal. they are not just "there to keep dirt out" at least on a NonTurbo.

you should take a pic of the seals you have on yours. I'm assuming if you have a Turbo they look like this:

glad you solved the problem though. good job!

chances are the increase in idle you heard while spraying the injectors was just what the PCV was sucking in below.

[I hate haters]

the "donut seals" are a vacuum seal. they are not just "there to keep dirt out" at least on a NonTurbo.

you should take a pic of the seals you have on yours. I'm assuming if you have a Turbo they look like this:

glad you solved the problem though. good job!

chances are the increase in idle you heard while spraying the injectors was just what the PCV was sucking in below.

When I was spraying around injector 5 I was hitting the gap between the manifold and the block created by that misplaced plate.

The donut seals in the picture from FCP site that you posted are not installed on my car. All I a have is the cap on the end of injector then o-ring and the plastic washer. I have those pics and will add them in the evening.

Thanks again.

[JBVolvo]

When I was spraying around injector 5 I was hitting the gap between the manifold and the block created by that misplaced plate.

The donut seals in the picture from FCP site that you posted are not installed on my car. All I a have is the cap on the end of injector then o-ring and the plastic washer. I have those pics and will add them in the evening.

Thanks again.

yeah, definately a different setup.

glad to hear its all set though. will watch for the pix

[jfo]

yeah, definately a different setup.

glad to hear its all set though. will watch for the pix

My S70 also does not have these seals.

[I hate haters]

yeah, definately a different setup.

glad to hear its all set though. will watch for the pix

Here are the pics

Bracket incorrectly installed by accident between manifold and engine block

Bracket being removed

Bracket reinstalled

Injectors

[JBVolvo]

Here are the pics

Bracket incorrectly installed by accident between manifold and engine block

Bracket being removed

Bracket reinstalled

Injectors

thanks for the pix