3828855 Volvo.Penta Bracket

Table 1
Required Tools    
Part Number    Part Name    Qty    
5P-4150     Tester Group     1    
5P-7448     Adapter     1    
6V-2170     Tube Assembly     1    
8S-2270     Fuel Collector     1    
1U-8857     Extension     1    
6V-6068     SAE J-967 Calibration Fluid     1    
Illustration 1 g00691280
(1) Fuel injection nozzle (2) Seal (3) Cap (4) Spacer (5) Gasket
Illustration 2 g00749601
(1) Fuel injection nozzle (5) Gasket
Run the engine at low idle.
Loosen the nut for the fuel supply line at each fuel injection nozzle (1). Listen for the low idle to decrease or become rough when the nuts are loosened at each cylinder.The fuel injection nozzle may be faulty if the following items occur during the test:
Engine rpm does not decrease.
The engine continues to run properly.
If the fuel injection nozzle is worn or damaged, remove the fuel injection nozzle for additional testing.Note: If leakage at the nut for the fuel supply line occurs, make sure that the fuel supply line and the nut for the fuel supply line are correctly aligned with the inlet connection of the fuel injection nozzle. Do not tighten the nut for the fuel supply line on the high pressure fuel line more than the recommended torque. If the nut is tightened more, the fuel line may become restricted or the threads of the fuel injection nozzle and the nut may be damaged.Inspection and Cleaning of the Fuel Injection Nozzles
Illustration 3 g00457586
Fuel injection nozzle components (1) Nut (2) Body (3) Shims (4) Spring (5) Rod (6) Spacer (7) Nozzle (8) Nozzle nut (9) GasketBefore a fuel injection nozzle is tested, remove any loose carbon from the tip of nozzle (7). Do not use abrasive material or a wire brush in order to clean the nozzle.Note: Extra care should be used in handling the fuel injection nozzle in order to prevent damage to the nozzle tip. A scratch or a burr could cause needle leakage or spray distortion. Dirt in the orifices of the nozzle tip can damage engine components. The dirt can also distort the spray pattern of the nozzle.Perform the following procedures to inspect the fuel injection nozzle.
Place nozzle nut (8) in a vise. Turn body (2) in a counterclockwise direction in order to disassemble the fuel injection nozzle.
Disassemble the fuel injection nozzle. Inspect each component for the following conditions: sticking, wear, scratches and cracks. If any component is damaged, the fuel injection nozzle must be replaced.Note: All components of the fuel injection nozzle must be kept clean. Keep the components in clean diesel fuel.Note: Before a new fuel injection nozzle is installed, soak the nozzle in a light oil. Calibration fluid can be used. Heat the oil to a temperature of 50 to 60 °C (122 to 130 °F). The oil will remove anti-corrosion material from the fuel injection nozzle.
Reassemble the fuel injection nozzle. Refer to the Specifications Module, "Fuel Injection Nozzle" topic for the correct torque.Leakage Test
Illustration 4 g00470020
Pressure test the fuel injection nozzle by using the 5P-4150 Nozzle Testing Group . (1) 5P-7448 Adapter (2) Fuel injection nozzle (3) 5P-4721 Tube (4) 1U-8857 Extension (5) 8S-2270 Fuel Collector (6) 8T-5313 Filter This procedure tests for leakage around all components of the fuel injection nozzle.
Connect fuel injection nozzle (2) to the tooling that is shown in Illustration 4.Position fuel injection nozzle (2) so that the direction of the fuel spray is into 1U-8857 Extension (4) and 8S-2270 Fuel Collector (5) .
Pump the pressure to about 1030 kPa (150 psi) below the opening pressure of fuel injection nozzle (2). Refer to the Specifications Module, "Fuel Injection Nozzles" topic for the correct setting of the opening pressure. Release the handle. When the pressure begins to decrease, note the time that is required for the pressure to decrease to approximately 0 kPa (0 psi). If fuel injection nozzle (2) is not faulty, the time will not be less than 5 seconds or more than 45 seconds.If the time that is required for the pressure to decrease to 0 kPa (0 psi) is less than 5 seconds, too much fuel is leaking around the valve needle. Replace fuel injection nozzle (2) .
Look for any leakage in the connection from the adapter to fuel injection nozzle (2). If leakage is visible, make sure that the components are tightened to the correct torque.If leakage continues to occur, unscrew the body of fuel injection nozzle (2) from the nozzle nut. Inspect the threaded surfaces for foreign particles and damage.If the faces are damaged, replace fuel injection nozzle (2) .If the faces are undamaged, clean the faces. Repeat Steps 1 and 2. If leakage continues to occur, replace the fuel injection nozzle.
Pump the pressure of the nozzle tester to approximately 2030 kPa (300 psi) below the opening pressure of fuel injection nozzle (2). Fuel should not collect on the tip of fuel injection nozzle (2) in a sufficient quantity in order to drip from the tip for at least ten seconds. A light dampness is acceptable.If the results of the tests are not acceptable, replace fuel injection nozzle (2) .Pressure Test
Ensure that you wear eye protection at all times during testing. When fuel injection nozzles are tested, test fluids travel through the orifices of the nozzle tip with high pressure. Under this amount of pressure, the test fluid can pierce the skin and cause serious injury to the operator. Always keep the tip of the fuel injection nozzle pointed away from the operator and into the fuel collector and extension.