21364517 Volvo.Penta Plug

Start By:a. remove rocker shaft assemblies 1. Thoroughly clean the area around each fuel line connection. Disconnect fuel injection line (1) and fuel injection nozzle (2) from the adapter.2. Remove clamp (3) and the spacer that holds the fuel injection nozzle in place.
Never use force to remove the fuel injection nozzles. If necessary, turn and pull the fuel injection nozzle out of the cylinder head.
3. Remove adapter (4) and fuel injection nozzle (2). The following steps are for installation of the fuel injection nozzles.
Before the fuel injection nozzles are installed, check for fuel leakage, the pressure at which the injection nozzle opens, and the amount of fuel (spray pattern) that comes out of the nozzle with tool (A). See Testing Fuel Injection Nozzles in Testing & Adjusting.
4. Remove carbon seal dam (6) with pliers. Remove compression seal (5). 5. Install a new compression seal on the nozzle. Install a new carbon seal dam with tool (B).6. Make sure the bore in the cylinder head and the fuel inlet fittings are clean.7. Install new O-ring seals on adapter (4) and fuel injection nozzle (2).8. Install the fuel injection nozzle in the head. Turn and push the nozzle into its correct position. Never put lubricant on the nozzle or bore in the cylinder head.9. Install adapter (4) in the head. Connect nozzle (2) and fuel injection line (1) to the adapter. Tighten the nuts to a torque of 40 7 N m (30 5 lb ft).10. Install the spacer and clamp (3) that hold the nozzle to the cylinder head.End By:a. install rocker shaft assembliesDisassemble & Assemble Fuel Injection Nozzles (9L7883)
Start By:a. remove fuel injection nozzles Do not disassemble any nozzle until testing has shown that disassembly is needed. Check each nozzle with tool (A) for leakage, opening pressure, and the shape and amount of fuel (spray pattern) coming out of the nozzle. Do not clean or make an adjustment to any nozzle that has a large (excessive) amount of return leakage. Excessive return leakage can be an indication of nozzle failures that can not be corrected with an adjustment or cleaning and can cause engine damage. See Testing 9L7883 Fuel Injection Nozzles in Testing & Adjusting.
Keep the work area and all tools extra clean. Be careful not to cause damage to the parts while the nozzles are disassembled and assembled.
1. Put the nozzle in tool (B). Put tool (B) and the nozzle in a vise. Do not put any part of a nozzle directly in a vise. Loosen locknut (1). 2. Loosen adjusting screw (2) approximately three turns. Loosen pressure screw (3). 3. While the nozzle is held in one hand, tilt the nozzle and remove locknut (1), adjusting screw (2), pressure screw (3), shims (7), spring (6), seat (5), and valve (4). 4. If the valve does not slide out of the nozzle, install tool (C) and remove valve (4) as follows:a. Push valve (4) into the nozzle with tool (C) until the valve is against the bottom of the nozzle.b. Push down on the body of tool (C) to engage the collet on valve (4).c. Turn the nut counterclockwise to tighten the collet on the valve and remove valve (4) from the nozzle body.5. Put the parts in solvent to loosen carbon and deposits of foreign material. The body is assembled with an epoxy material and must not be in contact with the solvent for more than one to two hours. See Special Instruction Form No. SEHS7292 for the correct method of cleaning the nozzle. The following steps are for assembly of the fuel injection nozzles. Make sure all of the parts have been thoroughly cleaned before assembling the nozzles. Flush the body to remove any debris or lapping compound.6. Put clean fuel on all of the parts.7. Put valve (4) in position in the body as shown.8. Install adjusting screw (2) into pressure screw (3). Turn the adjusting screw two or three turns and install locknut (1). Do not tighten the locknut.9. Put shims (7), spring (6), and seat (5) in position on the adjusting screw. The thicker shim of shims (7) must be against the screw.10. Put seat (5) in contact with valve (4) and push the valve into position in the body. Tighten pressure screw (3) by hand.11. Put the nozzle in position in tool (B). Put tool (B) and the nozzle in a vise. Tighten pressure screw (3) to a torque of 8.5 to 9.1 N m (75 to 80 lb in).12. Check the opening pressure of the nozzle as controlled by shims (7) with tool (A). See Testing 9L7883 Fuel Injection Nozzles, Opening Pressure Test in Testing & Adjusting.13. Check the valve lift adjustment as controlled by adjusting screw (2) with tool (A). See Testing 9L7883 Fuel Injection Nozzles, Valve Lift Adjustment in Testing & Adjusting. 14. Hold adjusting screw (2) with a screwdriver and tighten locknut (1) until the adjusting screw will not turn.15. Tighten the locknut to a torque of 4.0 to 4.5 N m (35 to 40 lb in).End By:a. install fuel injection nozzlesDisassemble & Assemble Fuel Injection Nozzles (9L6969 & 9N3979)
Start By:a. remove fuel injection nozzles Do not disassemble any nozzle until test has shown it is needed. Check each nozzle with tool (A) for leakage, the pressure at which the nozzle opens, and the shape and amount of fuel (spray pattern) that comes out of the nozzle. Do not clean or make an adjustment to any nozzle that has a large (excessive) amount of return leakage. Excessive return leakage can be an indication of nozzle failures that can not be corrected with an adjustment or cleaning and can cause engine damage. See Testing 9L6969 & 9N3979 Fuel Injection Nozzles in Testing & Adjusting.
Keep the work area and all tools extra clean. Be careful not to cause damage to the the parts while the nozzles are disassembled and assembled.
1. Remove cap (1) from the fuel injection nozzle.
If the lift adjustment screw is not turned counterclockwise one