3858508 Volvo.Penta Propeller

Table 1
Required Tools
Tool Part Number Part Description Qty
A 278-4138 Cap Kit 1
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.
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 and on wires and all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. This will help to prevent fluid loss and this helps to keep contaminants from entering the system.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
If the engine is equipped with a cover over the fuel system this will need to be removed.
Illustration 1 g01335193
Typical example
For engines with plastic clamps, make temporary identification marks on all the clamps to show position and orientation prior to removal. Use a suitable tool to remove plastic clamps (3) from the fuel injection lines (2). Care must be taken to avoid damage to the fuel injection lines. Discard the plastic clamp.
Illustration 2 g03095797
Typical example of later type clamp
For engines with later type clamps, make temporary identification marks on all the clamps to show position and orientation prior to removal. Remove bolt (15) from clamp (14). Remove clamp (14) from fuel injection line (2).
Slide the dust seal from the nut on the fuel injection.
Disconnect fuel injection line (2) from electronic unit injector (1).
Disconnect fuel injection line (2) from fuel manifold (4).
Remove fuel injection line (2). Discard the fuel injection line.
Plug the open port in fuel manifold (4) immediately. Use Tooling (A) in order to plug the open port in the fuel manifold.
Remove seal (5) from electronic unit injector (1) and from the base of the valve mechanism cover.
Plug the open port in electronic unit injector (1) immediately. Use Tooling (A) in order to plug the open port in the electronic unit injector.
Repeat Steps 5 through 12 in order to remove the remaining fuel injection lines from the fuel manifold to the electronic unit injectors.
Illustration 3 g01335194
Typical Example
If necessary, disconnect harness assemblies (8) from fuel injection pump (7). Slide locking tab (9) into the unlocked position. Disconnect harness assembly (8) from position sensor (10). Disconnect harness assemblies (8) from fuel injection pump (7). Position harness assemblies (8) so that the harness assemblies are clear of fuel injection line (6).
Illustration 4 g01335195
Illustration 5 g01335197
Remove bolts (11) from tube clips (12) that secure fuel injection line (6). Loosen allen head screws (13). Position the tube clips in order to allow removal of the fuel injection line.
Disconnect fuel injection line (6) at fuel injection pump (7).
Disconnect fuel injection line (6) at fuel manifold (4).
Plug all open ports immediately. Use Tooling (A) in order to plug the open ports in fuel manifold (4) and in fuel injection pump (7).
Remove fuel injection line (6).
Remove allen head screws (13) and tube clips (12) from fuel injection line (6). Discard the fuel injection line.