Hi Klaus and Dick. I figured out what both of you recommended, and the car is running because there were developments after I posted:

1. I used a coat hanger to fish out an errant o-ring and top seal that were down on the side of the engine. Though I tried to remove the rail carefully, these had popped off/free of one injector. Those top o-rings sure are tight.

2. Just as was wondering if I could reuse the pinched o-ring, I remembered I had the old regulator with o-ring. Sure enough - same o-ring. So I put that on to replace the damaged one.

3. I now examined the situation, and discovered how hard the injectors press into the rail. So, I arrived at your conclusion - all injectors press into the rail first. I didn't think of vaseline, and boy it would have helped! I rocked and twisted the injectors gently in .

3. At this point I thought "I'm getting this back together today." I dropped one of the 10mm bolts while installing, it went under a bracket down below and was harder to get than the seals ):

4. I finally got that bolt out, and proceeded to press the rail on in a very civil manner. It went in nice and smooth with a little rocking.

5. It is back together and running dry, and I am thrilled. So happy I saved that old regulator.

Thanks for your advice, even though I didn't get to read it. I thought my miscue earlier turned people off to replying. Regards, Don

I, also, put the injectors on the rail before seating them on the manifold. Don't over torque those 2 aluminum bolts!! They snap too easy :) Fortunately, the bolts are also easy to back out.

Klaus
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Please answer, we need to know if the advice is good or bad. The 164 has a new home, all I am left with are 2 turbos :)

What has worked for me is to install with vaseline on the O rings. Also, I put the injectors first and install the works into the head. The vaseline trick is one Volvo has recommended for years with all O rings. Go slow too as you suggest.

Hope it works,

dick