3853990 Volvo.Penta Sensor

Fuel System
Testing 9L9263 Fuel Injection Nozzles
8S2242 Nozzle Testing Group.8S2245 Injector Cleaning Tool Group.9S7354 Torque Wrench.9S3093 Adapter.Before testing a fuel injection pump or nozzle from an engine that is misfiring or puffing black smoke, a simple check can be made to determine which cylinder is causing the difficulty.With the engine running at a speed that makes the misfiring most pronounced, momentarily loosen the fuel line nut on an injection pump sufficiently to "cut out" that cylinder. Check each cylinder in the same manner. If one is found where loosening makes no difference in the irregular operation or causes puffing of black smoke to cease, the pump and valve for only that cylinder need be tested.Exhaust port temperature, when the engine is running at low idle speed, can be an indication of injection nozzle condition. Low temperature at an exhaust manifold port, indicates no fuel to the cylinder and a possibility of a clogged nozzle. Exceptionally high exhaust port temperature may indicate excess fuel injection caused by poor fuel cut off. Do not attempt to test or disassemble nozzles without the proper service tools.Before testing, remove loose carbon from the tip with the 8S2258 Brass Wire Brush. Remove the carbon seal dam and clean the groove and the body below the groove in the same manner. Any staining in this area is normal and not detrimental to the nozzle body. Carbon accumulations should be removed, but excessive brushing will remove the coating on the nozzle. Perform all test before cleaning or adjusting a nozzle. A test may show that the nozzle can not be used again.
When testing, keep the nozzle tip directed away from the operator and into the 8S2270 Fuel Collector to contain the spray. Fuel from the spray orifices can penetrate clothing and skin causing serious infection.
Connect nozzle (4) to tester (1) using tube assembly (2) and adapter (3). The nozzle may be tightened by hand if the 1H1023 Seal is not damaged.
Always use clean Kent-Moore J23300-585 or Shell 66631 calibration oil or equivalent when testing. Dirty test oil will damage nozzle components.
Kent-Moore J23300-585 calibration oil may be purchased from Kent-Moore Corp. 1501 South Jackson St., Jackson, Michigan 49203. Shell 66631 calibration oil may be purchased from Shell Oil Company.
CONNECTING NOZZLE TO TESTER
1. 8S2267 Nozzle Tester. 2. 8S2268 Tube Assembly. 3. 9S3093 Adapter. 4. Nozzle.Opening Pressure Test
1. Close the gauge protector valve and the on-off valve. Open the pump isolator valve. Flush the nozzle by operating the tester for 10 to 15 strokes at a rate of 60 strokes per minute.2. Open the gauge protector valve. Raise the pressure slowly until the nozzle valve opens. The gauge reading may drop sharply if the valve chatters, or may stay nearly constant when the valve opens. Opening pressures should be as listed in the chart. If opening pressure is less than 2200 psi (154.7 kg/cm2), do not use the nozzle again. Lack of chatter or atomized spray during Step 2 does not indicate a faulty valve. Used nozzles that have been cleaned, should be adjusted to 2750 to 2850 psi (193.3 to 200.4 kg/cm2) opening pressure.3. Adjust opening pressure, if necessary as follows: a) Remove the nozzle from the tester and secure it in the 8S2250 Nozzle Holding Tool. Loosen the adjusting screw locknut. Reconnect the nozzle, with the tip facing downward, to the tester.b) Back out the lift adjusting screw far enough to prevent bottoming when the pressure adjusting screw is turned.
Failure to back out the lift adjusting screw far enough will result in a bent valve or damage to the valve seat in the next step.
c) Turn the pressure adjusting screw clockwise to increase, or counterclockwise to decrease opening pressure. Do not tighten locknut at this time.Valve Lift Adjustment
1. With the opening pressure set correctly and while pumping test oil through the nozzle, hold the pressure adjusting screw and slowly turn the lift adjusting screw clockwise until the fuel ceases to flow.2. Check to be sure the valve is bottomed by raising the pressure 200 to 500 psi (14.06 to 35.15 kg/cm2) OVER the nozzle opening pressure.
Do not bend the valve or damage the valve seat by bottoming with too much force.
Some fuel may collect at the tip but a rapid dribble should not be apparent.3. Back out the lift adjusting screw 3/4 1/8 of a turn.4. Hold the pressure adjusting screw and tighten the locknut. See subject, TIGHTENING LOCKNUT.5. Recheck the opening pressure.Checking Seat Condition
1. Wrap the top of the fuel nozzle body (adjusting screw end) with a shop towel to absorb the leakage. Close the gauge protector valve.2. Point the nozzle tip into the 8S2270 Fuel Collector and operate the pump rapidly for at least five strokes to firmly seat the valve. Open the gauge protector valve. Dry the nozzle tip thoroughly.3. Raise the pressure at the nozzle to 250 to 300 psi (17.6 to 21.1 kg/cm2) UNDER opening pressure. If more than 3 drops of fuel should appear on the tip in 15 seconds, clean or replace the nozzle.Spray Pattern
The valve lift must be set properly before checking spray pattern. The amount of lift affects this characteristic.1. Close the gauge protector valve and the on-off valve. Open the pump isolator valve.2. Point the nozzle tip into the 8S2270 Fuel Collector.3. Raise pressure slowly and observe the spray pattern when fluid begins to flow through the nozzle. The spray must be equal and unifor