977897 Volvo.Penta Housing

Fuel Injection Nozzles
Fuel injection nozzles are subject to tip wear. Tip wear, a result of fuel contamination, can cause:* increased fuel consumption* black smoke* misfire* rough runningThe fuel injection nozzles should be cleaned, inspected, tested, and replaced if necessary. Removal and InstallationSpecial tooling is required for removing and installing the fuel injection nozzles. Refer to the Service Manual for information. Consult your Caterpillar dealer for assistance.Test/Exchange
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To prevent possible injury, turn the start switch OFF when changing fuel filters or water separator elements. Clean up fuel spills immediately.
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over any disconnected fuel system components.
Never wire brush or scrape a fuel injection nozzle. Wire brushing or scraping a fuel injection nozzle will damage the finely machined orifice. Proper tools for cleaning and testing fuel injection nozzles can be obtained from authorized Caterpillar dealers.
Abnormal engine running, smoke emission, and engine knock can be symptoms of a fuel injection nozzle malfunction. Each fuel injection nozzle must be isolated one at a time in order to determine which fuel injection nozzle is malfunctioning.1. Start the engine.
A fuel injection nozzle will be damaged if the top of the nozzle turns in the body. The engine will be damaged if a defective fuel injection nozzle is used because the fuel spray pattern that comes out of the nozzle will be incorrect. Fuel injection nozzles can be permanently damaged by twisting if only one wrench is used to loosen or tighten the fuel line nuts. DO NOT let the tops of the fuel injection nozzles turn when the fuel lines are loosened. Use one wrench to hold the fuel injection nozzle and use another wrench to loosen the fuel line nut.
2. Loosen each fuel line nut at the fuel injection pump, one at a time. A cloth or similar material must be used to prevent the fuel from spraying on the hot exhaust components. Tighten each fuel line nut before loosening the next fuel line nut.3. A defective fuel injection nozzle may be identified when a fuel line nut is loosened and: * the exhaust smoking is partially or completely eliminated* irregular running is not affectedA fuel injection nozzle suspected of being defective should be removed. A new fuel injection nozzle should be installed in the cylinder in order to determine if the fuel injection nozzle which was removed is defective.Turbocharger
Periodic inspection and cleaning is recommended for the turbocharger compressor housing (inlet side). Since the crankcase fumes are ingested through the inlet air system, oil and combustion by-products may collect in the turbocharger compressor.This buildup, over time, can contribute to loss of engine power, increased black smoke, and overall loss of engine efficiency. This buildup is only a possible contributor to these conditions.Operating the engine until the turbocharger fails can severely damage the turbocharger's compressor wheel and/or the engine. Damage to the turbocharger compressor wheel could allow parts from the compressor wheel to enter the engine cylinder, causing additional damage to the pistons, the valves, and the cylinder head.
Turbocharger bearing failures can cause large quantities of oil to enter the air inlet and exhaust systems. Loss of engine lubricant can result in serious engine damage.Minor leakage of a turbocharger housing under extended low idle operation will not cause problems as long as a turbocharger bearing failure has NOT occurred.When a turbocharger bearing failure is accompanied by a significant engine performance loss (exhaust smoke or engine speed up at no load), DO NOT continue engine operation until the turbocharger is repaired or replaced.
Cleaning, inspecting, and checking the turbocharger will minimize unscheduled downtime and reduce the chance for potential damage to other engine parts. Turbocharger components require precision clearances and balancing due to operation at high rotational (torsional) speeds. Severe Service Applications can accelerate component wear and may suggest the need to inspect the cartridge at more frequent intervals. Removal and InstallationRefer to the Service Manual or consult with your Caterpillar dealer for the turbocharger removal and installation procedure and for turbocharger specifications. Consult with your Caterpillar dealer for turbocharger repair or replacement options.Clean/Inspect/Check
1. Remove the exhaust outlet piping and air inlet piping from the turbocharger. Visually check for oil leaks.2. Turn the compressor wheel and turbine wheel by hand. The assembly should turn freely. Inspect the compressor wheel and turbine wheel for contact with the turbocharger housing. There should NOT be any visible signs of contact between the turbine or compressor wheel and the turbocharger housing. If there is any indication of contact between the a rotating wheel and the housing, the turbocharger should be reconditioned or replaced.3. Check the compressor wheel for cleanliness. If only the blade side of the wheel is dirty, dirt and/or moisture is passing through the air filtering system. If oil is found only on the back side of the wheel, a turbocharger oil seal leak may be indicated.The leak may be the result of extended engine operation at low idle or an inlet air line restriction (plugged air filters), which causes the turbocharger to "slobber".4. Use a dial indicator in order to check the end clearance on the turbocharger shaft. Attach the dial indicator point to the end of the turbocharger shaft. Push and pull the other end of the shaft. Note the total dial indicator reading. If the measured end play is greater than the Service Manual specifications, repair or replace the turbocharger. Measured end play less than the minimum Service Manual specifications could indicate carbon buildup on the turbine wheel. The turbocharger should be disassembled for cleaning and inspection if the measured end play is less than the minimum Service Manual specifications.5. Inspect the turbine housing bore for corrosion.6. Clean the turbocharger housing with standard shop solvents and a soft bristle brush.7. Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing. Refer to the Torque