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Diesel swirl flaps and injectors

Volvo S40, V50 (2004-), V70, XC70 (2008-), S60 (-2009), V70 P26 (2001-2007), S80 (2007-), C30, C70 (2006-), XC60 (-2017), XC90 (-2014)

Instructions for the replacement of the swirl flaps and injectors on the Volvo D5 engine, including the removal and install of the injectors. The injectors have to be taken out to remove the valve cover with the integrated intake manifold.
The pictures show the engine of a XC90 and XC70 P26, all models with the D5 engine are quite the same in this regard. However, the swirl flaps in the cylinder head are not present in all D5s.

Besides the swirl flap you need these parts according to Volvo:
- installation kit injector 5x
- sealing ring fuel return line 5x
- valve cover gasket
- hose clamp PCV system
- complete set of high pressure fuel lines

highly recommended:
- fuel return hose 1.5m
- injector solvent spray
- swirl flap linkage
- injector lubricant

During any work on the fuel system, alsways disconnect the battery for safety reasons. The injector fuel lines might be under high pressure, loosen them slowly and careful! Catch dripping fuel with paper towels. Never turn on the ignition with open fuel lines!

First take off the engine cover and the strut brace if necessary.

Unplug the camshaft sensor, the injector and the temperature sensor and put the wiring harness aside.

Unscrew the inlet hose on the manifold and the EGR and take it off. Take the hose off of the oil trap and and the PCV system and put it aside.

Now clean the whole area around the injector lines and the return lines, dust must not enter the fuel system! Volvo recommends isopropyl alcohol for cleaning since it does not harm plastic, but cleans well.

Unsrew the injector lines, put them aside, plug the fuel ports. We recommend an open end wrench to loosen the fuel lines, standard wrenches tend to round up the fittings.

Pull out the clamps of the return lines and pull out the return line straigt upwards. Pulling sideways or levering quickly breaks the return line.

Spray the injector seats with injector solvent, we recommend Skandix 1060549. The easier the injectors will come out, the smaller the risk of damaging them.

If an injector is stuck, you may use the puller Volvo 9997335 (Skandix 1064396) with a suitable sliding hammer.

If the injector is too stuck to pull it with this tool, unscrew the electronic part on top. In this case all holes in the surrounding area need to be plugged, because under the electronic part a spring and a washer will become loose, those must not enter the the other open injector seats. In that case you will need to take off the cylinder head, so take care to prevent this. After taking off the electronic part, you can srew on a lager sliding hammer adaptor with a larger sliding hammer. Always use the whole thread length and pull out the injector straight upward. If there is not enough space to do so, take off the hood.

If you unsrew the electronic part of the injector, the whole injector needs to be replaced or remanufactured by a specialist.

Now you can unscrew the valve cover and take it off. Clean the valve cover properly. Clean out the intake channels as good as possible, remove all soot from the area of the swirl flap to prevent it from jamming again in the near future.

Lever off the linkage off the ball and take the swirl flap with all bearings out of the cylinder head. Clean the inlet ports in the cylinder head and the bearing areas too.

Now you can put in the new swirl flap, some slicone spray might help. Put the linkage back on now, since it is easy now.

Now the injector seats and sealing areas need to be cleaned. Use rather soft cleaning brushes for the seats to not damage the aluminium. The soot needs to be removed completely, otherwise leaks may be possible. Also clean the injectors if you want to reuse them.

Before you install the valve cover, check the threads for the injector clamps for any damages, if the threads need to be repaired, you have to do it now! When the threads of the injector screws are damaged, we recommend our set Skandix 1078256. It contains rather long self tapping thread sleeves made from steel. Shorter thread sleeves will not work based on our experience: Our solution makes sure you get a strong and long lasting thread repair.

The rest of the install has to be done in reverse order. It is necessary to use the complete OEM installation kit for the injectors. The sealing ring and the clamp need to be replaced. When injector clamps are worn, the injectors might move into their seat due to the compression. In the worst case scenario the screws of the injector clamp might  break or pull the thread out of the cylinder head. So take care, even if you only need to repair one thread you have to repeat the whole procedure, since the valve cover has to be taken off to repair a thread.