Fuel Injector Removal 2105 S60 T5 2.0L B4204T11 Engine
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    1. #1
      Junior Member tttexpress's Avatar
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      Fuel Injector Removal 2105 S60 T5 2.0L B4204T11 Engine

      I am searching for instructions, tips and general information for removing and replacing the fuel injectors for a 2015.5 S60 T5 2.0L Drive-E B4204T11 engine. All older Volvos that I have owned the injectors either came out with the fuel rail or were easily removed with fuel rail off. This engine has them recessed and they did not come out with the fuel rail. I have the Volvo Special Tool for replacing the o-rings/seals but I do not want to damage the fuel injectors. They are solidly in place. Anyone with experience on this engine/version that can share tips?
      2015.5 S60 T5 Drive-E
      2012 S80 T6 Premier
      2008 S80 T6

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    3. #2
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      Sometimes they come out with the rail, sometimes they don't. If they don't, there is a special tool to pull them out.

    4. #3
      Junior Member tttexpress's Avatar
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      Thanks for the response. I have the Volvo Special Tool 9997498 (Extractor) but they wouldn't budge. I am disappointed with the tool as it is cheap and the clips straightened out. After more research and thought I went back and worked on them with considerable force and they finally came free. You also need Volvo Special Tool 9997501 and 9997502 for replacing the seals. One note - after getting the injectors out, I can see no way these would ever come out with the rail.

      And yes they went back in with ease.
      2015.5 S60 T5 Drive-E
      2012 S80 T6 Premier
      2008 S80 T6

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    6. #4
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      I would estimate I've had 10 fuel rails off. Only one time did all four injectors stay in the head and I had no trouble pulling them out with the special tool.

      Just curious, why are you replacing them? And how many miles do you have?

    7. #5
      Junior Member tttexpress's Avatar
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      I had one the T11 engines that rings go bad at approximately 100,000 miles. Mine went bad at 106,590 miles. Started showing signs of an issue around 104,000 miles and very quickly started drinking a quart of oil every 150 to 200 miles. So I replaced the engine and had to move the injectors from the old engine and I also put an injector seal kit on them since I had them out. I ran into several challenges during the process, mostly due to lack of available information. I will say I am impressed by the amount of engineering that it took for Volvo to cram so much stuff into such a small space and it not run extremely hot.
      2015.5 S60 T5 Drive-E
      2012 S80 T6 Premier
      2008 S80 T6

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