3803639 Volvo.Penta Alternator, exch

Table 1
Required Tools
Tool Part Number Part Description Qty
A 388-1289 Capping Kit 1
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
Illustration 1 g02539836
Clean the area around flow control valve (2) and fuel injection pump. Ensure that the area is free from contamination before beginning disassembly.
Disconnect harness assembly (3) from flow control valve (2).
Make temporary marks on the flow control valve and the fuel injection pump for installation purpose.
Remove Allen heads screws (1) from the flow control valve.
Remove the flow control valve from the fuel injection pump.
Use Tooling (A) in order to plug the fuel injection pump.
Remove O-ring seal (4) (not shown). Installation Procedure
Ensure that all component at free from wear and damage. If any part of the flow control valve is worn or damaged, the flow control valve must be replaced as an assembly.
Illustration 2 g02539836
Position a new O-ring seal (4) (not shown) onto the flow control valve assembly.
Check O-ring seal (4) (not shown) is correctly positioned. Ensure that O-ring seal is not damaged.
Lubricate O-ring seal (4) (not shown) with clean fuel. Note: Ensure that the O-ring seals are not damaged or misaligned.
Remove Tooling (A) from the fuel injection pump.
Install flow control valve (3) to the fuel injection pump.
Install Allen head screws (2) from the flow control valve repair kit.
Tighten Allen head screws (2) equally until the flow control valve is seated correctly onto the fuel injection pump. Note: Ensure that the Allen screws are tightened equally. Failure to ensure that the Allen screws are tightened equally will result in damage to the fuel injection pump.
Tighten the Allen head screws to a torque of 9 N m (80 lb in).
Connect harness assembly (1) to flow control valve (3).
Replace the filters for primary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Primary (Water Separator) Element - Replace" for the correct procedure.
Replace the filters for secondary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.
Turn the fuel supply to the ON position.
Turn the battery disconnect switch to the ON position.
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for more information. End By:
After replacement of the flow control valve, the fuel injection pump requires a high-pressure fuel pump calibration procedure to be performed. Refer to Troubleshooting, "Fuel Rail Pressure Problem" for the correct procedure.