60112001 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 System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
If the engine is equipped with an air compressor, remove the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove" for the correct procedure.
Illustration 1 g06183326
Position hose assembly (3) away from bracket (2).
Remove bolt (1) and bracket (2) from the cylinder head.
Disconnect harness assembly (5) from flow control valve (4).
Clean the area around flow control valve (4) and the fuel injection pump. Ensure that the area is free from contamination before beginning disassembly.
Make temporary marks on flow control valve and the fuel injection pump for installation purpose.
Remove Allen head bolts (6) from the flow control valve.
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Remove the flow control valve from the fuel injection pump. Remove O-ring seal (7).Installation Procedure
Ensure that all components are free from wear and damage. If any part of the flow control valve is worn or damaged, the flow control valve must be replaced as an assembly. The flow control valve kit contains the guide pins to install the flow control valve assembly.
Illustration 3 g06183353
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Flow control valve guide pins
Illustration 5 g06183326
Check that O-ring seal (7) is correctly positioned. Ensure that O-ring seal (7) is not damaged.Note: If the O-ring seal is damaged, a new flow control valve assembly must be installed.
Install guide pins into Position (X) on the fuel injection pump.Note: The guide pins are part of the flow control valve repair kit.
Lubricate O-ring seal (7) with clean fuel.Note: Ensure that the O-ring seal is not damaged or misaligned.
Position the flow control valve onto the guide pins.Note: Ensure that the flow control valve is correctly orientated
Install the flow control valve to the fuel injection pump.
Remove guide pins from the fuel injection pump.
Install Allen head screws (6).
Tighten Allen head screws (6) equally until the flow control valve is seated correctly onto the fuel injection pump.Note: Ensure that the Allen head screws are tightened equally. Failure to ensure that the Allen head screws are tightened equally will result in damage to the fuel injection pump.
Tighten the Allen head screws to a torque of 9 N m (80 lb in).
Position bracket (2) onto the cylinder head and install bolt (1). Tighten the bolt to a torque of 9 N m (80 lb in).
Install hose assembly (3) to the original position on bracket (2)
Connect harness assembly (5) to flow control valve (4).
Replace the filters for primary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Primary (Water Separator) Element - Replace" for the correct procedure.
Replace the filters for secondary fuel system. Refer to Operation and Maintenance Manual, "Fuel System Secondary Filter - Replace" for the correct procedure.
Turn the fuel supply to the ON position.
Turn the battery disconnect switch to the ON position.
Install the crankcase breather. Refer to Disassemble and Assemble, "Crankcase Breather - Install" for the correct procedure.
If the engine is equipped with an air compressor, install the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Install" for the correct procedure.
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for more information.
After replacement of the flow control valve, the fuel injection pump must be calibrated. Use the electronic service tool to perform "High Pressure Fuel Pump Calibration".