7746800_104 Volvo.Penta cables and terminals

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-8376 Capping Kit 1
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 battery disconnect switch to the OFF position.
Turn the fuel supply to the OFF position.
Illustration 1 g03411000
The water separator and fuel filter can be installed in any location on a machine. Ref to the Original Equipment Manufactures (OEM) for the correct location.
Make temporary identification marks on tube assemblies in order to show the correct position of the tube assemblies.
Place a suitable container below the fuel filter base in order to catch any fuel that might be spilled.
Disconnect tube assembly (3) and tube assembly (4) from the assembly of primary fuel filter (5).
Use Tooling (A) in order to plug the tube assemblies. Use Tooling (A) in order to cap the connection on the primary fuel filter.
Disconnect the OEM harness assembly from the connection on harness assembly (7) for water in fuel sensor (6).
Disconnect the OEM harness assembly from the connection on harness assembly (1).
Remove bolts (2) and remove the assembly of primary fuel filter (5) from the mounting. Support the primary fuel filter as the bolts are removed.
Illustration 2 g03411001
If necessary, follow Step 11.a through Step 11.d in order to disassembly the assembly of primary fuel filter (5).
Remove connection (9) and remove O-ring seal (8).
Remove connection (11) and remove O-ring seal (10).
Remove water in fuel sensor (6) and remove O-ring seal (13) (not shown).
Remove the filter element from fuel filter canister (12). Refer to Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element - Replace" for the correct procedure. Installation Procedure
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.
Ensure that the fuel filter base is clean and free from damage. If necessary, replace the complete fuel filter base and filter assembly.
Illustration 3 g03411001
If necessary, follow Step 2.a through Step 2.d in order to assembly primary fuel filter (5).
Install a new O-ring seal (8) to connection (9). Install connection (9) to primary fuel filter (5). Tighten the connection to a torque of 20 N m (177 lb in).
Install a new O-ring seal (10) to connection (11). Install connection (11) to primary fuel filter (3). Tighten the connection to a torque of 20 N m (177 lb in).
Install a new O-ring seal (13) (not shown) to water in fuel sensor (6). Install water in fuel sensor (6). Tighten water in fuel sensor (6) hand tight.
Install a new filter element to fuel filter canister (12). Refer to Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element - Replace" for the correct procedure.
Illustration 4 g03411000
Position the assembly of primary fuel filter (3) onto the mounting.
Install bolts (2) to the assembly of primary fuel filter (3). For M8 8.8 graded bolts, tighten the bolts to a torque of 22 N m (195 lb in).For M10 8.8 graded bolts, tighten the bolts to a torque of 44 N m (32 lb ft).For bolts that are graded differently, refer to the OEM for the correct torque values.
Ensure that the plastic tube assemblies are installed in the original positions. Failure to connect the plastic tube assemblies to the correct ports will allow contamination to enter the fuel system. Serious damage to the engine will result if contaminated fuel enters the fuel system.
Remove plug from tube assembly (3). Remove cap from the connection on the primary fuel filter.
Connect tube assembly (3) to primary fuel filter (5).
Remove plug from tube assembly (4). Remove cap from the connection on the primary fuel filter.
Connect tube assembly (4) to primary fuel filter (5).
Connect the OEM harness assembly to the connection on harness assembly (7) for water in fuel sensor (6).
Connect the OEM harness assembly to the connection on harness assembly (1).
Turn the fuel supply to the ON position.
Turn the battery disconnect switch to the ON position. End By:
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.