843903 Volvo.Penta Plug

Fuel Injection Nozzles
Exchange
Whenever the engine performs in such a manner that a fuel injection nozzle is suspected of causing irregular running, smoking or knocking, isolate each fuel injection nozzle, one at a time, to determine the malfunctioning nozzle.1. Start the engine.
Do not loosen nuts at the top of fuel nozzles. The nozzles will be damaged if the top of the nozzle turns in the body when the fuel lines are loosened. The engine will be damaged if a defective fuel injection nozzle is used because of the shape of fuel (spray pattern) that comes out of the nozzles will be incorrect.
2. Loosen the fuel injection line nut at the fuel pump, one at a time, with the engine running. Be sure to tighten each fuel line nut after the test, before the next fuel line nut is loosened.3. When a cylinder is found where the loosened fuel line nut does not make a difference in engine performance or smoking, have that cylinder injection nozzle tested to determine whether the injection nozzle can be cleaned and used again or exchanged for a new nozzle.4. Stop the engine.To Remove And Install Injection Nozzles
Refer to the Service Manual for your engine to remove and install injection nozzles. For complete fuel injection nozzle test information, refer to Special Instruction Form SEHS7292 or consult your authorized Caterpillar dealer.This Special Instruction contains information and procedures to test the fuel injectors for: * Pressure Loss* Valve Opening Pressure (VOP)* Tip Leakage* Spray Pattern* Flushing Procedure Do not use a fuel injector in the engine unless the injector is tested for the items listed above and all test results are within test specifications.Your Caterpillar dealer has the necessary equipment to perform this maintenance.Air Compressor
Rebuild or Exchange
Failure to purge the air brake and auxiliary air systems before removing the air compressor could cause personal injury. Do not disconnect the air line from the air compressor governor without purging air from the air brake and auxiliary air systems.
Visually check for fluid leaks.1. Release the air pressure in the air tank until the air pressure is zero.2. Remove discharge fittings (1) and inspect compressor discharge port and discharge line for excessive carbon deposits. The discharge line must be cleaned or replaced and the compressor checked more thoroughly if there is excessive carbon build-up in either the discharge line or compressor discharge port.Refer to the Service Manual for your engine to remove and install the air compressor.Turbocharger
Rebuild or Exchange
The cost incurred to maintain the turbocharger before failure as recommended could be significantly less than if you wait until your turbocharger fails.By maintaining the turbocharger before failure, you will minimize unscheduled downtime and reduce the chances for potential damage to other engine parts. When you reduce the risk of unscheduled downtime and costly repairs, you conserve cash that can be budgeted for use more profitably elsewhere.If you operate the engine until a turbocharger fails, you could cause additional damage to the engine. For example, a failed turbocharger might cause severe engine damage that could result in cracks in the cylinder head, a piston seizure or other potential damage to the engine.If you choose to operate the engine until the turbocharger fails, your repair costs could be as much as twenty-five times or more compared to the repair before failure cost. This excessive cost is due to additional engine damage that could have been prevented.Our recommended maintenance intervals for performing preventive maintenance on the turbocharger are based on experience and gathered data relative to the expectant life of the engine and its components. These maintenance intervals were developed as a service for your use to minimize unexpected and costly repairs as well as to serve as an aid to reduce your operating costs.Failure to follow our recommendations could result in unexpected, costly repairs and unscheduled downtime.Caterpillar recommends that the most cost effective method for the turbocharger is to rebuild or exchange the unit before it fails.Maintenance Options
Repair Kits - These useful kits can be obtained from your Caterpillar dealer. These kits include all the necessary parts and instructions to repair the turbocharger, in either your own maintenance shop or at a servicing dealer's facility. Repair kits simplify parts ordering, help speed repairs and reduce parts cost. Remanufactured - This process uses manufacturing techniques and procedures to restore the turbocharger to "like-new" performance capability. This process always involves an end product which conforms to the manufacturer's "original" functional specifications. New - Replace with a new turbocharger.Caterpillar Recommendation
Caterpillar recommends that the use of a Remanufactured turbocharger is the most cost effective option.For removal and installation of turbochargers, see the Service Manual for this engine or consult your Caterpillar dealer.Engine Mounts
Inspect/Check
Front engine mount shown.Caterpillar recommends checking the engine mounts for deterioration and proper bolt torque. This will prevent excessive engine vibration caused from improper mounting. See your Service Manual or OEM truck manufacturer for recommended torque values.Vibration Damper
Inspect/Check
Inspect the damper for rubber deterioration and movement of the outer ring relative to the inner hub. Damage to, or failure of, the damper will increase torsional vibrations and result in damage to the crankshaft and other engine components. A failing vibration damper will cause more gear train noise at variable points in the speed range. The vibration damper has marks on the hub (1) and ring (2). These marks will indicate the condition of the vibration damper. If the marks are not in alignment, the rubber seal between the ring and the hub has separated from the ring and/or hub. If the marks are not in alignment, install a new vibration damper.A used vibration damper can have a visual wobble (movement to the front and rear when in rotation) on the outer ring. This does not mean a replacement is necessary since some wobble of the outer ring is normal. To see if the amount of wobble is acceptable, or replacement is necessary, check the damper with the procedure in the Testing and Adjusting section of the Service Manual.