20542751 Volvo.Penta Plug

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 276-1216 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.
Use a deep socket to install the electrical connections to the electronic unit injectors. Use of incorrect tooling will result in damage to the electronic unit injectors.
Illustration 1 g02353356
Injector code
If the original electronic unit injector (8) is installed , ensure that the electronic unit injector is installed into the original position.
If a replacement electronic unit 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 electronic unit 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 electronic unit injector.
Illustration 2 g02313273
If necessary, follow Step 4a through Step 4e 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 4a through Step 4e to install the remaining harness assemblies to the cylinder head.
Ensure that the fuel inlet port of the electronic unit injector is capped. Ensure that the electronic unit injector is clean.
Illustration 3 g01972153
New sealing washer (12) should only be installed if the original electronic unit injector (8) is to be reused.
On installing an original electronic unit 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 electronic unit injector (8).Note: Ensure that the nozzle for the electronic unit 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 electronic unit injector are not damaged and in place.Note: Do not lubricate the O-ring seal.
Ensure that the seat for the electronic unit 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 electronic unit injector (8). Align the assembly of electronic unit injector (8) to the bore for the electronic unit injector in the cylinder head.Note: Ensure that the clamp is correctly positioned onto the electronic unit injector.
Push only on injector clamp (10) to install electronic unit injector (8). Do not apply pressure on any other part of the electronic unit injector. Ensure that the electronic unit 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 electronic unit injector (8). Install a new seal (4) to electronic unit 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 electronic unit injector and the fuel manifold. Tighten the nuts hand tight.
Use Tooling (A) to tighten Torx screw (9) to a torque of 22 N m (195 lb in).Note: Tooling (A) must be used to ensure no damage to the electronic unit injector.
Use Tooling (E) to tighten the fuel injection line to a torque of 55 N m