2008 Volvo S40 D5 2.4 Diesel

[Paulm81]

I have swapped my C30 for a S40 D5 and starting to wish I never, I noticed bubbling around injectors 2/3/4, so I replaced the copper sealant washers on all 5 injectors and it’s still bubbling?? I’m not a mechanic yet will try if looks do able. Have I done something wrong? I removed 1 injector at a time cleaned injector and replaced seal washer and before refitting I cleaned bore and facing as much as possible before putting it back. The injector has no movement so don’t understand why still leaking? Is there supposed to be any rubber orings on injector at all?

Will try uploading video tomorrow

[Clan]

Originally Posted by Paulm81

I have swapped my C30 for a S40 D5 and starting to wish I never, I noticed bubbling around injectors 2/3/4, so I replaced the copper sealant washers on all 5 injectors and it’s still bubbling?? I’m not a mechanic yet will try if looks do able. Have I done something wrong? I removed 1 injector at a time cleaned injector and replaced seal washer and before refitting I cleaned bore and facing as much as possible before putting it back. The injector has no movement so don’t understand why still leaking? Is there supposed to be any rubber orings on injector at all?

Will try uploading video tomorrow

you need 5 new fitting kits , the spring plate bends it will never clamp with the same force twice. Also are the seats down inside the head perfectly clean bright alluminium ? Be careful to torge the holding bolts correctly or you will strip them .

[Paulm81]

Originally Posted by Clan

you need 5 new fitting kits , the spring plate bends it will never clamp with the same force twice. Also are the seats down inside the head perfectly clean bright alluminium ? Be careful to torge the holding bolts correctly or you will strip them .

Thanks for the quick response it’s appreciated 👍
So i need to replace the clamps and the 8mm bolts with another new set of seal washers?
Obviously can’t reuse them

[Clan]

Originally Posted by Paulm81

Thanks for the quick response it’s appreciated 👍
So i need to replace the clamps and the 8mm bolts with another new set of seal washers?
Obviously can’t reuse them

yes its all in the kit , look down the tubes in the head , the sealing face must be completely clean shiny aluminium . you need 5 x kits you don't get it all in one kit ,, a bit confusing !

bolt torque is 13nm