3861502 Volvo.Penta Decal

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 g00846800
(1) Fuel injector
(2) Sealing washer
Run the engine at low idle.
Loosen the nut for the fuel supply line at each fuel injector (1). Listen for the low idle to decrease or become rough when the nuts are loosened at each cylinder. The fuel injector 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 injector is worn or damaged, remove the fuel injector 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 injector. 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 injector and the nut may be damaged.Inspection and Cleaning of the Fuel Injectors
Before a fuel injector is tested, remove any loose carbon from the tip of the nozzle. 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 injector 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.Leakage Test
Illustration 2 g00470020
5P-4150 Nozzle Testing Group
(1) 5P-7448 Adapter
(2) Fuel injection nozzle
(3) 6V-2170 Tube Assembly
(4) 1U-8857 Extension
(5) 8S-2270 Fuel Collector
(6) 8T-5313 Filter This procedure tests for leakage around all components of the fuel injector.
Connect the fuel injector (2) to suitable tooling that is similar to the Illustration 2. Position fuel injector (2) so that the direction of the fuel spray is into the extension (4) and the fuel collector (5).
Pump the pressure to about 2030 kPa (294 psi) below the opening pressure of the fuel injector (2). Refer to Specifications, "Fuel Injectors" 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 the fuel injector (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 injector (2).
Look for any leakage in the connection from the adapter to the fuel injector (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 the fuel injector (2) from the nozzle nut. Inspect the threaded surfaces for foreign particles and damage.If the faces are damaged, replace the fuel injector (2).If the faces are undamaged, clean the faces. Repeat Steps 1 and 2. If leakage continues to occur, replace the fuel injector.
Pump the pressure of the injector tester to approximately 2030 kPa (294 psi) below the opening pressure of fuel injector (2). Fuel should not collect on the tip of the fuel injector (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 the fuel injector (2).Pressure Test
Ensure that you wear eye protection at all times during testing. When fuel injectors 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 injector pointed away from the operator and into the fuel collector and extension.
Illustration 3 g00470020
5P-4150 Nozzle Testing Group
(1) 5P-7448 Adapter
(2) Fuel injection nozzle
(3) 6V-2170 Tube Assembly
(4) 1U-8857 Extension
(5) 8S-2270 Fuel Collector
(6) 8T-5313 Filter
Do not use dirty test fluids when you test fuel injectors. Also, do not test fuel injectors unless you have the correct service tools.The use of dirty test fluids and the use of incorrect service tools will result in damage to the fuel injectors.
Note: This procedure is a test of the opening pressure of the fuel injector.
Connect the fuel injection nozzle (2) to the tooling that is shown in Illustration 3. The spray from fuel injection nozzle (2) must be directed into 1U-8857 Extension (4) and 8S-2270 Fuel Collector (5).Use clean 6V-6068 Calibration Fluid when the fuel injection nozzles are tested. The calibration fluid is similar to SAE J-967 (ISO 4113) oil.
Close the gauge protector valve. Close the shutoff valve. Open the pump isolator valve. Flush the fuel injector (2) by operating the nozzle tester. Operate the nozzle tester for 10 to 15 strokes at a rate of approximately sixty strokes per minute.
Open the gauge protector valve. Slowly increase the pressure until the valve in the fuel injector (2) opens. Note the highest pressure indication on the dial indicator before the pointer moves to 0 kPa (0 psi). This highest pressure indication is the opening pressure of fuel injector (2). The opening pressure occurs when the valve needle is lifted from the nozzle seat. Refer to Specifications, "Fuel Injection Nozzles" for the correct pressure settings. If the opening pressure is not within the range of the setting which is given in the table, the fuel injector (2) must be replaced.