836425 Volvo.Penta Cover

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.
Ensure that all open ports are plugged or capped.
Illustration 1 g03817937
Illustration 2 g06594323
Low Flow Banjo (3) Bolt And High Flow Banjo Bolt (7) Identification
Illustration 3 g03817946
Make temporary marks on hose and hose clamps for installation only.
Using a suitable tool, position hose clamp (2) and away from hose (1).
Make temporary marks on low flow banjo bolt (3) and high flow banjo bolt (7) for installation purposes. Refer to Illustration 2 to correctly identify the banjo bolts.
Remove low flow banjo bolt (3) and seal washers (4). Remove high flow banjo bolt (7) and sealing washers (6).
Remove pipe (5) from hose (1) and remove pipe (5) from engine.
Disconnect harness (11) from fuel rail (9).
Remove bolt (8) and bolt (10). Remove fuel rail (9) from engine. Discard all old sealing washers.Install Procedure
Illustration 4 g03817946
Position fuel rail (9) on engine.
Loosely install bolt (8) and bolt (10). Connect harness assembly (11) to the fuel manifold pressure sensor.
Illustration 5 g03817937
Position new hose clamp (2) onto pipe (5). Install pipe (5) into hose (1). Position pipe (5) onto the engine.
There is an engine failure risk if the high flow banjo bolt and low flow banjo bolt are swapped over during installation.
Illustration 6 g06594323
Low Flow Banjo (3) Bolt And High Flow Banjo Bolt (7) Identification
Install low flow banjo (3) and new washers (4). Install high flow banjo (7) and new washers (6).Note: Ensure low flow banjo bolt (3) and high flow banjo bolt (7) are installed in the original positions.Note: On certain engines a low flow banjo bolt may be fitted to the fuel manifold (Rail) refer to Illustration 6 to correctly identify a low flow banjo bolt.
Using a suitable tool, position new hose clamp (2) onto hose (1), in the position noted on removal. Tighten banjo bolts (3) and (7) to a torque of 20 N m (177 lb in).
Illustration 7 g03818073Note: Loosely install the fuel injection lines
Loosely install fuel lines (17), (16), (15), (14), and fuel line (13).
Loosely install clamps (18).
Tighten bolt (8) and bolt (10) to a torque of 26 N m (230 lb in).
Illustration 8 g03818142
Ensure that isolator (20) and (21) are positioned correctly. Tighten nut (22) and bolt (19) to a torque of 3 N m (27 lb in).