20875082 Volvo.Penta Service cover

Table 1
Required Tools
Tool Part Number Part Description Qty
A T410437 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 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.
Note: Cover harness injector connectors during removal to prevent ingress of fluid into the harness connectors seals otherwise connection to the injectors may not be possible.Note: Place temporary identification marks on all hoses, hose assemblies, wires and, tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. Plugging all hose assemblies and tube assemblies will prevent fluid loss and will keep contaminants from entering the system.Note: Plug or cap all open ports with new plugs or caps.Note: Electronic unit injectors must be removed in pairs.
Illustration 1 g06456586
Remove fuel injection lines (6). Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove" for the correct procedure.
Remove injector leak-off pipes (1). Refer to Disassembly and Assembly, "Fuel Lines - Remove and Install" for the correct procedure.
Disconnect harness assemblies (5) from electronic unit injectors (4).Note: Make a temporary mark on the wiring harness assembly to ensure that the wiring harness assembly is connected to the correct electronic unit injectors during assembly.
Illustration 2 g06157087
Remove nut (2) from injector clamp (3). Discard the nut and clamp.Note: If the injector clamp nut is loosened, Caterpillar recommend that the nut, clamp and stud are replaced.Note: Make a temporary mark on the electronic unit injectors to ensure that the electronic unit injectors are reinstalled in the original location.
Remove electronic unit injectors (4) as a pair from the cylinder head. Ensure that the electronic unit injectors are removed squarely from the cylinder head. Always handle electronic unit injectors with care.
Remove injector clamp (3) from electronic unit injectors (4).
Remove O-ring seals (7) from electronic unit injectors (4).
Remove sealing washers (8) from the electronic unit injectors. Sealing washers that are not present on the electronic unit injectors must be removed from the bores for the electronic unit injectors. Inspect the bores of the electronic unit injectors in the cylinder head.
Illustration 3 g06158557
Remove stud (11) from the cylinder head. Discard the stud.
If necessary, follow Step 4 through Step 9 to remove remaining electronic unit injectors (4).
Illustration 4 g06157096
Inspect seals (10) in valve mechanism cover (9) for leaks and damage. If necessary, use suitable tooling to remove the seals from the valve mechanism cover.