243903 Volvo.Penta Rotor

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     298-5564     T40 Torx Socket     1    
D     1U-5718     Vacuum Pump     1    
169-7372 Fluid Sampling Bottle     1    
4C-4057 Tube
7.9 mm (0.31 inch) Outside Diameter     1    
E     367-2771     Wrench     1    
F     247-5377     Torque Wrench     1    
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training.Before begining 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.
Use a deep socket in order to remove the electrical connections from the electronic unit injectors. Use of incorrect tooling will result in damage to the electronic unit injectors.
Illustration 1 g01973053
Injector code
If a replacement electronic unit injector is installed, the correct injector code must be programmed into the electronic control module. Refer to Troubleshooting, "Injector Code - Calibrate" for the correct procedure. The code that is required to obtain the injector code is located at Position (X) .Note: Record Code (X) before the electronic unit injector is installed.
Use Tooling (D) in order to remove any fuel from the cylinder.Note: Evacuate as much fuel as possible from the cylinder before installing the electronic unit injector.
Illustration 2 g02047333
If necessary, follow Step 3.a through Step 3.e in order to install harness assemblies (6) to cylinder head (17) .
Install a new O-ring seal (14) to harness assembly (6) .Note: Do not lubricate the O-ring seal.
Install harness assembly (6) to cylinder head (17) .
Install a new bolt (15) to harness assembly (6) . Tighten the bolt to a torque of 5.5 N m (49 lb in).
Install new assemblies of the cable strap (13) to harness assembly (6) .Note: Ensure that the cable straps meet the Original Equipment Manufactures (OEM) specification. Ensure that the assemblies of the cable strap are correctly installed into the cylinder head.
Connect harness assembly (16) to harness assembly (6) .
If necessary, repeat Step 3.a through Step 3.f in order to install the remaining harness assemblies to the cylinder head.
Ensure that the fuel inlet port of the electronic unit injector is capped. Ensure that the electronic unit injector is clean.
Illustration 3 g01972153
On installing an original electronic unit injector, install a new O-ring seal (11) .Note: Do not lubricate the O-ring seal.
Use a suitable tool in order to install a new sealing washer (12) to electronic unit injector (8) .Note: Ensure that the nozzle for the electronic unit injector is not damaged in any way on installation of the new sealing washer.
Ensure that O-ring seal (12) and sealing washer (12) on a new electronic unit injector are not damaged and in place.Note: Do not lubricate the O-ring seal.
Ensure that the seat for the electronic unit injector in the cylinder head is clean and free from damage. Ensure that the sealing washer has been removed from the cylinder head.
Illustration 4 g01971773
Position clamp (10) between the valve springs. Align electronic unit injector (8) to the bore for the electronic unit injector in the cylinder head. Install the clamp to the electronic unit injector. Ensure that the electronic unit injector is pushed firmly against the seat in the cylinder head.
Install a new Torx screw (9) to clamp (10) . Tighten the Torx screw finger tight.
Remove the cap from electronic unit injector (8) . Install a new seal (4) to electronic unit injector (8) and to the cylinder head. Ensure that the flange on the seal is flush with the cylinder head.
Remove the plugs from the new fuel injection line. Loosely install the fuel injection line. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.Note: Ensure that the ends of the fuel injection line are seated in the electronic unit injector and the fuel manifold. Tighten the nuts finger tight.
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