Well, after 2 weeks I FINALLY got MOST of the right parts from our CRACK (smoking?) parts department.

It would appear that Volvo has known about this possibility for some time as the Fuel Rail Ass'y for 92-97 has been pulled from inventory and superceded by the 98 up design.

Looking at the two, side-by-side, it would appear that this plug failure was thought to be caused by excess transmitted vibration. The new version has no direct contact with the manifold. Instead, you must thread in two wide shoulder spacers into the formost and rearmost mounting holes and the rail then bolts to the top of the spacers. It ends up being rather suspended, over the intake runners, instead of being bolted to it.

You will need at least two of these spacers, not 1 like the parts guy swears it calls for. Get three since they are cheap and VERY easy to break off. I broke one. Had to drill and retap the hole.

Also, when mounting the injectors into the rail, the retainer strip no longer will wrap around each injectors body. Instead it slips in to the slots up near the tail of the injector.

There are two slots on each injector. LEARN FROM MY MISTAKE. Align the strip with the lower most slots, nearest to the injector tail. If you align with the upper one there will not be enough reach for the injector noses to seat firmly within the runner(s).

Then, if you are dumb, like me, you will turn each spacer a few more times to grow some clearance and you will snap it right off.

Once done, it ran great! No Leaks, No Problems.