20825289 Volvo.Penta Pipe

Table 1
Required Tools
Tool Part Number Part Description Qty
A 298-5564 T40 Torx Socket 1
B 268-1968 Pry Bar 1
C 370-8376 Plugs and Caps 1 Start By:
Remove the rocker shaft assembly.
Remove the fuel injection lines.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
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.Dispose of all fluids according to local regulations and mandates.
Note: Place identification marks on all hoses, on all hose assemblies, on wires and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. Plugging all hose assemblies and tube assemblies will prevent fluid loss. Plugging all hose assemblies and tube assemblies will keep contaminants from entering the system.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
Illustration 1 g06140592
Make a temporary mark on valve bridges (2) to show the location and orientation. Remove valve bridges (2).Note: Identification will ensure that the valve bridges can be reinstalled in the original location and the original orientation.
Remove seal (1) from the cylinder head and fuel injector (5).
Make a temporary mark on wiring harness assembly (3) to show the location and orientation.
Use a deep socket to remove connections (4) from fuel injector (5).
Use Tooling (A) to remove Torx screw (6) from clamp (7). Discard the Torx screw.Note: Tooling (A) must be used to ensure no damage to the fuel injector.
Illustration 2 g06140616
Make a temporary mark on fuel injector (5) to show the original location of the fuel injector.
Temporarily remove Tooling (C) from the fuel injector.
Use Tooling (B) to pry beneath clamp (7) and free fuel injector (5) from the cylinder head.Note: Always handle fuel injectors with care.
Immediately replace Tooling (C) onto the fuel injector.
If fuel injector (5) is to be reused, Follow Step 13 through Step 15 to remove sealing washer (9) and O-ring seal (8).
Use a suitable tool to remove sealing washer (9) from fuel injector (5). Ensure that the sealing washer is removed from the cylinder head.Note: Ensure that the nozzle for the fuel injector is not damaged in any way on removal of the sealing washer.
Install Tooling (C) to the nozzle for fuel injector (5) and the open port of the fuel injector.
Remove O-ring seal (8) from fuel injector (5).
If necessary, repeat Step 3 through Step 15 to remove the remaining fuel injector.
Illustration 3 g06140618
If necessary, follow Steps 17.a through 17.f to remove harness assemblies (3) from cylinder head (13).
Cut cable straps (10).
Unscrew the remaining sections of the cable straps from the cylinder head.
Disconnect harness assembly (12) from harness assembly (3).
Remove bolt (11) for harness assembly (3).
Withdraw harness assembly (3) from cylinder head (13).
If necessary, repeat Step 17.a through Step 17.f to remove the remaining harness assemblies from the cylinder head.