21098575 Volvo.Penta Pipe

Table 1
Required Tools
Tool Part Number Part Description Qty
A 298-5564 T40 Torx Socket 1
D 1U-5718 Vacuum Pump 1
169-7372 Fluid Sampling Bottle 1
4C-4057 Tube
7.9 mm (0.31 inch) Outside Diameter 1
E 336-0703 Injector Pipe Nut Tool 1
F 247-5377 Torque Wrench 1
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training.Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information.Refer to Systems Operation, Testing and Adjusting Manual, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
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.
Illustration 1 g02353356
Injector code
If the original fuel injector (8) is installed , ensure that the fuel injector is installed into the original position.
If a replacement fuel injector is installed, the correct injector code must be programmed into the electronic control module. Refer to Troubleshooting, "Injector Code - Calibrate" for more information. The code that is required is at Position (X).Note: Record Code (X) before the fuel injector is installed.
Use Tooling (D) to remove any fuel from the cylinder.Note: Evacuate as much fuel as possible from the cylinder before installing the fuel injector.
Illustration 2 g02313273
If necessary, follow Step 4.a through Step 4.e to install a new harness assembly (6) to cylinder head (16).
Install a new harness assembly (6) to cylinder head (16).Note: Do not lubricate the O-ring seal.
Install a new bolt (14) to harness assembly (6). Tighten the bolt to a torque of 5.5 N m (49 lb in).
Install new assemblies of cable strap (13) for harness assembly (6) to cylinder head (16).Note: Ensure that the assemblies of the cable strap are correctly installed into the cylinder head.
Connect harness assembly (15) to harness assembly (6).
If necessary, repeat Step 4.a through Step 4.e to install the remaining harness assemblies to the cylinder head.
Ensure that the fuel inlet port of the fuel injector is capped. Ensure that the fuel injector is clean.
Illustration 3 g01972153
Install new sealing washer (12) if original fuel injector (8) is to be reused.
On installing an original fuel injector, install a new O-ring seal (11).Note: Do not lubricate the O-ring seal.
Use a suitable tool to install a new sealing washer (12) to fuel injector (8).Note: Ensure that the nozzle for the fuel injector is not damaged in any way on installation of the new sealing washer.
Ensure that O-ring seal (11) and sealing washer (12) on a new fuel injector are not damaged and in place.Note: Do not lubricate the O-ring seal.
Ensure that the seat for the fuel injector in the cylinder head is clean and free from damage. Ensure that the sealing washer has been removed from the cylinder head.
Illustration 4 g01971773
Position clamp (10) onto fuel injector (8). Align the assembly of fuel injector (8) to the bore for the fuel injector in the cylinder head.Note: Ensure that the clamp is correctly positioned onto the fuel injector.
Push only on injector clamp (10) to install fuel injector (8). Do not apply pressure on any other part of the fuel injector. Ensure that the fuel injector is pushed firmly against the seat in the cylinder head.
Install a new Torx screw (9) to clamp (10). Tighten the Torx screw finger tight.
Remove the cap from fuel injector (8). Install a new seal (4) to fuel injector (8) and to the cylinder head. Ensure that the flange on the seal is flush with the cylinder head.
Remove the plugs from the new fuel injection line. Install the fuel injection line hand tight. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.Note: Ensure that the ends of the fuel injection line are seated into the fuel injector and the fuel manifold. Tighten the nuts hand tight.
Use Tooling (A) to tighten Torx screw (9) to a torque of 27 N m (239 lb in).Note: Tooling (A) must be used to ensure no damage to the fuel injector.
Use Tooling (E) to tighten the fuel injection line to a torque of 50 N m (37 lb ft). Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.
Use a deep socket to install harness assembly (6) to fuel injector (8). Use Tooling (F) to tighten connections (7) to a torque of 2.0 N m (18 lb in).
If necessary, repeat Step 1 through Step 18 to install the remaining fuel injectors.
Illustration 5 g01973093
The correct location of valve bridges