824774 Volvo.Penta Fork

Start By:a. remove valve covers FLUID SPILLAGE CONTAINMENTCare must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
Do not let the tops of the fuel nozzles turn when the fuel lines are loosened. The nozzles will be damaged if the top of the nozzles turn in the body.
1. Use Tooling (A), and remove inner fuel injection lines (1). Install caps and plugs on all fuel injection line openings to keep dirt out of the fuel system. 2. Remove seal (2) from fuel injection line (1) if necessary. 3. Remove screw (3) from clamp (4) that holds fuel injection nozzle (5) in position. Clamp (4) cannot be removed until the fuel injection nozzle is lifted approximately 25.0 mm (1.00 in). 4. Remove the fuel injection nozzles with Tooling (B) as follows: a. Install 6V-6983 Adapter (6) and 6V-4152 Screw (7) into nozzle assembly (5). b. Install 6V-6982 Tube Assembly (8) over the 6V-4152 Screw. Use 2S-5658 Washer (9) and 1B-2406 Nut (10) on the 6V-4152 Screw to pull the fuel injection nozzle from the adapter.
A replacement of compression seal washer (11) and of carbon dam seal (12) must be made each time the fuel nozzle is removed. Be sure that the replacement compression seal washer (11) is the same color code and part number as the original compression seal washer. If the wrong thickness washer is used, engine damage could occur. See the topic "Fuel Injection Nozzle And Adapter" in the Specifications Manual for more detailed information.
5. Remove compression seal washer (11) and carbon dam seal (12) from fuel injection nozzle (5).Install Fuel Injection Nozzles
1. Install compression seal washer (1), and use Tool (A) to install carbon dam seal (2) on the fuel injection nozzle.2. Make reference to Special Instruction SEHS7292 for the use of Tooling (C). 3. Use Tool (D) to clean adapter bore (3) for the fuel injection nozzle. Use an open end wrench or a tap driver to turn Tool (D). 4. Install fuel injection nozzle (4) and clamp (5) as a unit. Install the bolt in the clamp to hold it in place. 5. Install O-ring seal (6) on the inner fuel injection line.
Do not let the tops of the fuel nozzles turn when the fuel lines are tightened. The nozzles will be damaged if the top of the nozzles turn in the body.
6. Install inner fuel injection line (7). Use Tooling (B) to tighten the inner fuel line nuts to a torque of 40 7 N m (30 5 lb ft). For more information regarding the fuel injection nozzles, see the topic "Fuel Injection Nozzle And Adapter" in the Specification Manual.End By:a. install valve covers