3854020 Volvo.Penta Repair kit

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-8376 Capping 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.
Turn the fuel supply to the OFF position.
Turn the battery disconnect switch to the OFF position.
If necessary, remove fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure.
If necessary, remove crankcase breather canister filter. Refer to Operation and Maintenance Manual, "Engine Crankcase Breather Element - Replace" for the correct procedure.
Illustration 1 g03585598
Clean the area around flow control valve (3) and fuel injection pump (1). Ensure that the area is free from contamination before beginning disassembly.
Disconnect harness assembly (4) from flow control valve (3).
Make temporary marks on flow control valve (3) and the fuel injection pump for installation purpose.
Remove allen heads screws (2) from flow control valve (3).
Remove flow control valve (3) from fuel injection pump (1).
Use Tooling (A) to plug fuel injection pump (1).
Remove O-ring seal (5) and O-ring seal (6).
Use Tooling (A) to cap flow control valve (3). Installation Procedure
Ensure that all component at 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.
Illustration 2 g03585598
Illustration 3 g03411799
Flow control valve guide pins
Remove cap from flow control valve (3). Position new O-ring seal (5) and new O-ring seal (6) onto flow control valve (3).
Install guide pins into Position (X) on fuel injection pump (1).
Lubricate O-ring seal (5) and O-ring seal (6) with clean fuel. Note: Ensure that the O-ring seal is not damaged or misaligned.
Remove plug from fuel injection pump (1). Align flow control valve (3) onto guide pins.
Install flow control valve (3) to fuel injection pump (1).
Remove guide pins from the fuel injection pump.
Install allen head screws (2) from the flow control valve repair kit.
Tighten allen head screws (2) equally until the flow control valve is seated correctly onto the fuel injection pump. Note: Ensure that the allen screws are tightened equally. Failure to ensure that the allen screws are tightened equally will result in damage to the fuel injection pump.
Tighten allen head screws (2) to a torque of 9 N m (80 lb in).
Connect harness assembly (4) to flow control valve (3).
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.
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for more information. End By:
Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.
After replacement of the flow control valve, the fuel injection pump requires a high-pressure fuel pump calibration procedure to be performed. Refer to Troubleshooting, "Fuel Rail Pressure Problem" for the correct procedure.