3581420 Volvo.Penta Injection pump

Installation Procedure
Exhaust Gas Valve (NRS) - Install (Method 1)
Illustration 1 g06515069
Install new O-ring seal (7) (not shown) to exhaust gas valve (3).
Install exhaust gas valve (3) to exhaust gas valve elbow (8).
Position bracket (6) onto the exhaust gas valve and install Allen bolts (1). Tighten the Allen bolts to a torque of 9 N m (80 lb in).
Position harness (4) onto bracket (6) and install cable straps (5).Note: Ensure that the cable straps meet the Original Equipment Manufacturers (OEM) specification.
Connect harness assembly (2) and slide the locking tab into the locked position.
If the Diesel Particulate Filter (DPF) assembly is mounted on the valve mechanism cover, installation of the DPF assembly will be necessary after the NRS induction mixer has been installed. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Install" for the correct procedure.Exhaust Gas Valve (NRS) - Install (Method 2)
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Illustration 2 g02509136
Illustration 3 g02509196
Position a new gasket (34) onto locating Pins (X). Ensure that the gasket is correctly orientated onto the NRS induction mixer.
Position a new gasket (18) onto tube assembly (19).
Illustration 4 g02503497
Illustration 5 g02503496
Illustration 6 g02614076
Position the assembly of NRS induction mixer (32) onto the cylinder head.
Loosely install bolts (33) to the assembly of NRS induction mixer (32).
Loosely install bolts (17) to tube assembly (18). Ensure that gasket (18) is still correctly located on tube assembly (18).
Tighten bolts (33) to a torque of 22 N m (195 lb in).
Tighten bolts (17) to a torque of 9 N m (80 lb in).
Position a new gasket (30) onto NRS induction mixer ensure that the gasket is correctly located onto Pins (Y).
Position a new gasket (28) onto the spacer ensure that the gasket is correctly located onto Pins (Y).
Position spacer (29) onto inlet connection (26).Note: Ensure that the spacer is correctly orientated.
Install assembly of inlet connection (26). Install bolts (27) and nut (31).Note: Ensure that the inlet connection is correctly orientated.
Tighten bolts (27) and nut (31) to a torque of 22 N m (195 lb in).
Position a new sealing washer (25) (not shown) onto banjo bolt (24). Install the banjo bolt onto tube assembly (23) and install the remaining new sealing washer (25) (not shown).
Tighten banjo bolt (24) to a torque of 15 N m (133 lb in).
Install the bolt for tube assembly (23). Tighten bolts to a torque of 22 N m (195 lb in).
Position hose assembly (20) onto the inlet connection (26). Tighten hose clamp (21) securely.
Connect plastic tube assembly (22) to the valve mechanism cover and the crankcase breather canister. Refer to Disassembly and Assembly, "Crankcase Breather - Install" for the correct procedure.
Illustration 7 g02503476
If necessary, connect harness assembly (14) for the glow plug.
Position engine harness assembly onto NRS induction mixer. Ensure that the engine harness assembly is correctly routed.
Connect harness assembly (13) to temperature sensor (16) for the NRS induction mixer. Slide locking tab (15) into the locked position.
Install new cable the straps to temperature sensor (16).Note: Ensure that the cable straps meet Original Equipment Manufacturers (OEM) specifications.
Connect wiring harness assembly (10) to inlet pressure sensor (12). Slide locking tab (11) into the locked position.
Connect wiring harness assembly (4) to outlet pressure sensor (6). Slide locking tab (5) into the locked position.
Connect wiring harness assembly (3) to wiring harness assembly (1) for the wastegate solenoid. Slide locking tab (2) into the locked position.
Connect harness assembly (7) to NRS valve (9). Slide locking tab (8) into the locked position.
Install new cable straps to the engine wiring harness. Ensure that the engine wiring harness is correctly routed and that all cable straps are correctly positioned.Note: Ensure that the cable straps meet OEM specifications.
If necessary, install secondary fuel filter base and bracket. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure.
If necessary, install water separator and fuel filter (Primary). Refer to Disassembly and Assembly, "Water Separator and Fuel Filter (Primary) - Remove and Install" for the correct procedure.
If the Diesel Particulate Filter (DPF) assembly is mounted on the valve mechanism cover, installation of the DPF assembly will be necessary after the NRS induction mixer has been installed. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Install" for the correct procedure.