3589530 Volvo.Penta Cap

Table 1
Required Tools
Tool Part Number Part Description Qty
A 298-5564 T40 Torx Socket 1
B 268-1968 Pry Bar 1
C 370-8376 Capping Kit 1 Start By:
Remove the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft - Remove" for the correct procedure.
Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure.
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 authorised personnel that have the correct training.Before begining 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 Systems Operation, Testing and Adjusting Manual, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Use a deep socket in order to remove the electrical connections from the electronic unit injectors. Use of incorrect tooling will result in damage to the electronic unit injectors.
Note: Put identification marks on all hoses, on all hose assemblies, on wires and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. That helps to prevent fluid loss and plugging helps to keep contaminants from entering the system.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
Illustration 1 g02475251
Place a suitable container below tube assembly (1) to catch any fuel that might be spilled.
Use a suitable tool in Position (X) to hold tube assembly (1) as nut on hose assembly (2) is loosened.
Loosen the nut on hose assembly (2) to allow the fuel to drain from tube assembly (1).
Remove hose assembly (2) from tube assembly (1). Remove O-ring seal (3) (not shown).
Use Tooling (C) to cap the hose assembly immediately. Use Tooling (C) to plug the tube assembly immediately.
Illustration 2 g01971773
Make a temporary mark on valve bridges (5) to show the location and orientation.Note: Identification will ensure that the valve bridges can be reinstalled in the original location and the original orientation.
Remove seal (4) from the cylinder head and electronic unit injector (8).
Make a temporary mark on wiring harness assembly (6) to show the location and orientation.
Use a deep socket to remove connections (7) from electronic unit injector (8).
Use Tooling (A) to remove Torx screw (9) from clamp (10). Discard the Torx screw.
Illustration 3 g01971775
Illustration 4 g01972153
Use Tooling (B) to pry beneath clamp (10) and free electronic unit injector (8) from the cylinder head.Note: Always handle electronic unit injectors with care.
Use a suitable tool to remove sealing washer (12) from electronic unit injector (8). Ensure that the sealing washer is removed from the cylinder head.Note: Ensure that the nozzle for the electronic unit injector is not damaged in any way on removal of the sealing washer.
Install Tooling (C) to the nozzle for electronic unit injector (8) and the open port of the electronic unit injector.
Remove O-ring seal (11) from electronic unit injector (8).
If necessary, repeat Step 8 through Step 16 to remove the remaining electronic unit injectors.
Illustration 5 g02047333
If necessary, follow Steps 18a through 18g to remove harness assemblies (6) from cylinder head (17).
Place a temporary identification mark on harness assembly (6) for the electronic unit injectors.
Cut cable straps (13) and remove the remaining sections of the cable straps from the cylinder head.
Disconnect harness assembly (16) from harness assembly (6).
Remove bolt (15) for harness assembly (6).
Withdraw harness assembly (6) from cylinder head (17).
Remove O-ring seal (14) from harness assembly (6).
If necessary, repeat Step 18a through Step 18f to remove the remaining harness assemblies from the cylinder head.