860644 Volvo.Penta Hose

Table 1
Required Tools
Tool Part Number Part Description Qty
A 164-5924 Injector Bore Gauge 1
B 4C-5027 Tap Wrench 1
C 4C-6161 Tube Brush 1
D 164-5927(1) Wire Brush 1
E 4C-6774 Vacuum Gun Kit 1
F 8T-7765 Surface Reconditioning Pad 1
G 1U-5512 Abrasive Material 1
H 9U-6862 Tapered Brush 1
I 4C-4057 Tube 1
J 1U-5718 Vacuum Pump 1
K 1U-5814 Bottle Assembly 1
(1) This tool is optional. The 164-5927 Wire Brush has a shortened handle that facilitates use in tight engine compartments.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
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.Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Clean The Carbon Deposits
Illustration 1 g00337772
This is an example of a typical injector sleeve. (1) 120 degree angled surface of the injector sleeve. The lower O-ring seal contacts the injector sleeve in this area. (2) The injector tip fits in this bore in the injector sleeve.
Cleanliness is essential to the proper sealing of the injector. All carbon deposits should be removed from the injector sleeve and the bore (2). Carbon deposits should also be removed from the 120 degree angled surface (1) at the bottom of the injector sleeve.
Failure to properly clean any of the listed areas may cause an improper seal at the lower injector O-ring seal. This could result in tip damage or injector failure due to leakage of combustion gas into the fuel passage.
Illustration 2 g00337773
This is an example of a typical injector. The entire lower portion of the injector should be clean. Extra attention should be paid to the lower O-ring seal groove (3) and the adjacent surface.
Clean The 120° Angled Surface Of The Injector Sleeve
The fine grade of the Scotch Brite material is preferred. Scotch Brite is available from the Tools And Shop Products Guide as the 1U-5512 Cut & Polish Roll and as the 8T-7765 Surface Reconditioning Pad.The following procedure is the preferred method of cleaning the 120° angled surface of the sleeve (1):
Place a 38 mm (1.5 inch) square piece of Scotch Brite material on the end of a 9U-6862 Tapered Brush.
Twist the 9U-6862 Tapered Brush with the 4C-5027 Tap Wrench against lower surface (1) of the sleeve bore.Note: Cleaning the carbon deposits should not be difficult. The use of power tools is not necessary.
When the angled surface of the sleeve is thoroughly cleaned, the surface will be smooth and shiny. The entire sleeve bore should be cleaned so that any loose carbon particles will be removed.Clean The Bore Of The Injector Sleeve
Clean the bore (2) of the injector sleeve. If the injector sleeve is installed in the engine, use the 4C-6161 Tube Brush or the 164-5927 Wire Brush to clean the carbon deposits from the bore. If the injector sleeve has been removed from the engine, a 9U-6102 Reamer can be used in addition to the brush to remove the carbon deposits from the bore.Note: The 164-5927 Tube Brush may be substituted for the 4C-6161 Tube Brush. The 164-5927 Tube Brush has a shortened handle that facilitates use in tight engine compartments.Note: The 4C-6774 Vacuum Gun Kit is available for cleaning the loose material from the sleeve bore.
After the injector sleeve has been cleaned with the 9U-6102 Reamer or the 4C-6161 Tube Brush, use the 164-5924 Injector Sleeve Bore Gauge to determine that an adequate amount of carbon has been removed.
Illustration 3 g00811595
Gauge (A) should be inserted into the injector sleeve until the cross pin contacts the top of sleeve (4). This ensures that the gauge will extend completely through the hole. The gauge should not contact the piston. If the gauge can be easily seated, enough of the carbon has been cleaned out.
If the gauge cannot pass through the sleeve bore and the seat correctly, additional cleaning is necessary.
If additional cleaning has been tried and the gauge will not pass through the injector sleeve