856831 Volvo.Penta Oil cooler

Table 1
Tools Needed
Part Number Part Name Quantity
5P-4150 Nozzle Testing Group 1
5P-4718 Adapter 1
6V-2170 Tube 1
8S-2245 Injector Cleaning Tool Group 1
8S-2270 Fuel Collector 1
1U-8857 Extension Tube 1
6V-6068 Calibration Fluid 1 Perform the following procedure in order to identify the fuel injection nozzles which do not operate correctly.
Illustration 1 g00804139
Fuel injection nozzles and lines
(1) Nuts for the fuel injection lines
Run the engine at low idle.
Loosen the nut of the fuel injection line (1) at each fuel injection nozzle. Listen for the low idle to decrease or become rough at each cylinder.
The fuel injection nozzle has a defect when the nut of the fuel injection line (1) is loosened and the following items do not occur: idle decreases and rough idle. Remove the fuel injection nozzle for additional testing. Note: If leakage at the nut of the fuel line occurs, make sure that the fuel line and the nut are correctly aligned with the inlet connection of the fuel injection nozzle. Do not tighten the nuts on the high pressure fuel lines more than the recommended torque. If the nut is tightened more, the fuel line may be restricted or the threads of the fuel injection nozzle and the nut may be damaged.Pressure Test And Adjustment
Ensure that you wear eye protection at all times during testing. When fuel injection nozzles 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 injection nozzle pointed away from the operator and into the fuel collector and extension.
Illustration 2 g00804566
5P-4150 Nozzle Testing Group
(1) 5P-7448 Adapter
(2) Fuel injection nozzle
(3) 6V-2170 Tube
(4) 1U-8857 Extension Tube
(5) 8S-2270 Fuel Collector
(6) 8T-5313 Filter
Do not use dirty test fluids when you test fuel injection nozzles. Also, do not test fuel injection nozzles 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 fuel injection nozzles.
Refer to Illustration 2 in order to connect the fuel injection nozzle (2) to the tooling. The spray from the fuel injection nozzle must be directed into the 1U-8857 Extension Tube (4) and the 8S-2270 Fuel Collector (5).Use clean 6V-6068 Calibration Fluid when the fuel injection nozzles are tested. The calibration fluid is equivalent to SAE J-967 (ISO 4113) oil.
Close the gauge protector valve. Close the shutoff valve. Open the pump isolator valve. In order to flush the fuel injection nozzle, operate the nozzle tester for 10 to 15 strokes by using a rate of approximately 60 strokes per minute.
Open the gauge protector valve. Slowly increase the pressure until the valve in the fuel injection nozzle opens. Note the highest pressure indication on the gauge before the pointer decreases to 0 kPa (0 psi). This highest pressure indication is the opening pressure of the fuel injection nozzle. The opening pressure is defined when the valve needle is lifted from the valve seat. Refer to the table in the Specifications Module, "Fuel Injection Nozzles" for correct pressure settings. If the opening pressure is not within the range of the setting which is listed in the table, the opening pressure of the fuel injection nozzle must be adjusted.
Loosen the cap nut (8). Turn the pressure adjuster (10) clockwise in order to increase the pressure. Turn the pressure adjuster counterclockwise in order to decrease the pressure.
Tighten the cap nut (8). Check the opening pressure again on the nozzle tester. If the pressure is correct, remove the fuel injection nozzle from the nozzle tester. Note: Before the fuel injection nozzle is removed from the tester, be sure that the gauge protector valve is closed in order to prevent damage to the pressure gauge.Cleaning The Fuel Injection Nozzles
Before a fuel injection nozzle is tested, remove any loose carbon from the tip of the fuel injection nozzle.
Fasten the fuel injection nozzle in a holder or a vise with brass jaws. Release the pressure on the nozzle holder spring by loosening the adjuster. Remove the nozzle cap nut and the nozzle with the correct size of wrench.
Illustration 3 g00804568
(7) Fuel inlet
(8) Cap nut
(9) Fuel return
(10) Pressure adjuster
(11) Spring for pressure adjuster
(12) Body
(13) Spindle for spring
(14) Retaining nut for fuel injection nozzle
(15) Valve needle
(16) Nozzle
(17) Seat washer
(18) Orifices
Remove the valve needle (15) from the nozzle body. Use the Brass Wire Brush in the 8S-2245 Injector Cleaning Tool Group in order to remove any carbon that may be on the body (12).
Clean the seat of the valve needle (15) and the fuel reservoir with a Scraper. The Scraper is in the 8S-2245 Injector Cleaning Tool Group. Note: Use extra care not to break a wire of the brass wire brush in an orifice (18) or passage in the fuel injection nozzle. Removal of a broken wire is very difficult. Removal of a broken wire may damage the fuel injection nozzle.
Clean the orifices (18) in the nozzle tip with a cleaning wire. If the size is not known, carefully try different sizes of wires in order to find the correct wire. Insert the wire into the orifice. Slowly rotate the wire in order to clean the orifice. Note: Extra