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How to remove and install a turbo of the Volvo 850

Volvo 850 service & repair manual


1995 Volvo 850

Volvo – Removal, Overhaul & Installation
850 – Turbo


Removal, overhaul, and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.


WARNING: Always relieve fuel pressure before disconnecting any fuel injection-related component. DO NOT allow fuel to contact engine or electrical components.


1) Remove throttle pulley cover. Remove shield over valve on fuel rail. Connect Adapter (999 5484) to Fuel Drainage Unit (981 2270,
2273 and 2282). Connect adapter to valve on fuel rail, ensuring adapter is in locked position. Start fuel drainage unit. Unlock adapter. Raise and support vehicle.
2) Remove fuel filter valve cap located under vehicle.
Connect Vent Hose (999 5480) to valve before fuel filter. System drain time is about 2 minutes.


Removal & Installation
1) Fuel pump is located in fuel tank. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. On station wagon models, lift
luggage compartment floor cover and fold back carpet. On sedan models, tilt right rear seat forward. On all models, remove luggage
compartment carpet and right wheel housing panel.
NOTE: On some versions with a soft panel, it may be sufficient to fold back a corner of the panel.
2) Remove cover above fuel pump collar. Disconnect fuel pump connector. Carefully disconnect quick-release couplings on delivery and return lines. Remove fuel pump collar. Lift out fuel pump. Remove rubber seal. To install, reverse removal procedure. Tighten fuel pump collar to specification. See TORQUE SPECIFICATIONS.
WARNING: If fuel pump is removed for a long period of time, reinstall fuel pump collar to avoid tank swelling. If collar is not reinstalled, it may be difficult to install at a later time.
volvo 850 fuel pump removal service repair manual tutorial
Fig. 1: Removing Fuel Pump Collar
Courtesy of Volvo Cars of America, Inc.


CAUTION: Do not pry on injectors with a screwdriver or pinch injector pin with pliers during removal.
Removal & Installation
Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Unplug electrical connector from injector. Remove upper charge air pipe, fuel rail cover, and fuel line clips. Mount Clamps (999 5533) on injectors. Press in clamp to ensure it is seated firmly against injector. Screw down adjusting screw until clamping piece is in
contact with fuel rail, and tighten another half turn. Push out
injector. To install, reverse removal procedure.


Application Ft. Lbs. (N.m) EGR Valve Pipe …………………………….. 37 (50)
Fuel Pump Collar …………………………… 30 (41)
Knock Sensor ………………………………. 15 (20)
INCH Lbs. Fuel Rail Bolt …………………………….. 84 (10)


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