3588439 Volvo.Penta Plug

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.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning 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.
Note: Put 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. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
Illustration 1 g01243702
The fuel manifold is shown with fuel injection lines in position.
Illustration 2 g01763053
The fuel manifold is shown with fuel injection lines in position.
If necessary, remove fuel pressure sensor (4). Refer to Disassembly and Assembly, "Fuel Pressure Sensor - Remove and Install".
If fuel pressure sensor (4) does not require removal, slide locking tab (3) into the unlocked position. Disconnect the plug on harness assembly (7) from fuel pressure sensor (4).
Disconnect tube assembly (6) from fuel pressure relief valve (5). The tube assembly can be secured with a nut or with a banjo bolt. Immediately cap the open port in the pressure relief valve with a new cap. Immediately plug the open end of the tube assembly with a new plug.
If tube assembly (6) is secured with a banjo bolt, remove banjo bolt (9) and sealing washers (10). Refer to Illustration 2.
Illustration 3 g01800633
If necessary, remove fuel pressure relief valve (5). Use a deep socket in order to remove the fuel pressure relief valve. Note: The fuel pressure relief valve should only be removed at Position (X). The fuel pressure relief valve is a two-piece assembly which should not be disassembled.
Remove bolts (2) from fuel manifold (1). Note the position of any brackets that are secured by the bolts.
Remove fuel manifold (1) from mounting bracket (8).
If necessary, remove the bolts and remove mounting bracket (8). Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 276-1216 Injector Pipe Nut Tool 1
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning 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.
Ensure that all ports on the fuel manifold are capped. Ensure that the fuel manifold is externally clean and free from damage. Note: Do not install a fuel manifold that has not been capped. All caps must be left in place until the fuel injection lines or the fuel pressure sensor are installed.
Illustration 4 g01243702
The fuel manifold is shown with fuel injection lines in position.
Illustration 5 g01763053
The fuel manifold is shown with fuel injection lines in position.
If necessary, install mounting bracket (8) and install the bolts. Tighten the bolts to a torque of 22 N m (16 lb ft).
Position fuel manifold (1) onto mounting bracket (8). Install bolts (2) to the fuel manifold finger tight. Ensure that any brackets that are secured by bolts (2) are installed in the correct position.
Loosely install a new set of fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for more information.
Tighten bolts (2) to a torque of 22 N m (16 lb ft).
Use Tooling (A) to