31293424 Volvo.Penta Crankshaft

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.
Contact with high pressure fuel may cause personal injury or death. Wait 60 seconds after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines.
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.
Cleanliness is an important factor. Clean the exterior of the engine before the removal procedure. Ensure the area around the Fuel Manifold and the Fuel Lines are thoroughly cleaned. This action will prevent contaminants from entering the internal mechanism. Before replacing any Fuel Lines, follow the instructions that are listed below. Replace the Fuel Lines with the correct Fuel Lines Group.
Note: The following procedures were written for the complete removal of all of the fuel lines and clamps. If specific fuel lines need to be replaced, then only remove those fuel lines and clamps that need replacement.
Turn the fuel supply to the OFF position.
Disconnect the battery. Refer to Operation and Maintenance Manual, "Battery or Battery Cable - Disconnect".
Illustration 1 g02540880
Remove hose (1). Remove fuel filter assembly (2) and position out of the way.
Illustration 2 g02540916
Disconnect harness assemblies (3).
Remove nuts (4) and remove studs (5) and the spacers.
Illustration 3 g02540958
Remove bolt (7) and position harness assembly (6) out of the way.
Illustration 4 g02541017
Remove the bolt (8) and remove the clamp assembly. Discard the clamp assembly.
Remove nuts (16), (12), and (13). Remove the corresponding clamp assemblies and discard the clamp assemblies.
Loosen nuts (9) and (11). Remove fuel line (10) and discard the fuel line. Repeat for the remaining fuel lines.
Loosen nuts (14) and (17). Remove fuel line (15) and discard the fuel line. Installation Procedure
Fuel injection lines MUST only be used once. Discard all fuel injection lines after use.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Make sure that the fuel line caps remain in position until the fuel line is positioned near the corresponding ports in order to prevent contamination. Ensure that the areas around the rail and fuel lines are thoroughly clean before continuing this procedure. If any parts are worn or damaged, use new parts for replacement. Cleanliness is an important factor. Ensure that no debris gets introduced into the fuel system during the installation procedure. If any parts are worn or damaged, use new parts for replacement.Note: Make sure that the fuel line caps remain in position until the fuel line is positioned near the corresponding ports in order to prevent contamination.
Install fuel lines (15) and (10) in the reverse order of removal.
Install a new fuel line (10). Hand tighten nuts (9) and (11) on each end of the fuel line. Repeat for the remaining fuel lines.
Install a new fuel line (15). Hand tighten nuts (14) and (17).
Position the clamp assembly and install bolt (8). Hand tighten the bolt. Failure to place the grommet correctly on the fuel line could result in a failed fuel line.
Position the clamp assembly and install nuts (16), (12), and (13). Hand tighten the nuts. Failure to place the grommet correctly on the fuel line could result in a failed fuel line. Note: Ensure that the fuel lines are centered in the nuts prior to tightening. Do not use excessive force or bending in order to assemble the fuel lines.
Tighten nuts (17) and (11) at the fuel rail to a torque of 27 3 N m (239 27 lb in).
Tighten nuts (14) and (9) to a torque of 27 3 N m (239 27 lb in).
Tighten bolt (8) and nuts (16), (12), and (13) to a torque of 12 3 N m (105 27 lb in).