839504 Volvo.Penta Shift mechanism

Table 1
Required Tools    
Part Number     Part Name     Qty    
5P-4150     Tester Group     1    
5P-7448     Adapter     1    
6V-2170     Tube Assembly     1    
8S-2270     Fuel Collector     1    
1U-8857     Extension     1    
6V-6068     SAE J-967 Calibration Fluid     1    
8S-2245     Injector Cleaning Tool Group     1    
Illustration 1 g00569255
Fuel injection nozzle assembly (1) Holder assembly (2) Shim (3) Pressure spring (4) Gasket (5) Pin (6) Gasket (7) Fuel injection nozzle (8) Retaining nut
Start the engine and run the engine at low idle.
Loosen the nut for fuel supply line at each fuel injection nozzle. Listen for the low idle to decrease at each cylinder. Also, listen for the low idle to become rough at each cylinder.
The fuel injection nozzle may be damaged if the items that follow occur:
Engine rpm does not decrease.
The engine continues to run poorly.Remove the fuel injection nozzle from the engine cylinder head for additional testing.Note: If leakage at the nut for fuel supply line occurs, make sure that the fuel supply line and the nut for the fuel supply line are correctly aligned with the inlet connection of the fuel injection nozzle. Do not tighten the nut for the fuel supply line on the high pressure fuel line more than the recommended torque. If the nut is tightened more, the fuel line may become restricted or the threads of the fuel injection nozzle and the nut may be damaged.Cleaning Of Fuel Injection Nozzles
Personal injury can result from improper handling of chemicals.Make sure you use all the necessary protective equipment required to do the job.Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any product used to clean the components.Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of cleaning agents.
Do not use a steel brush or wire wheel to clean the nozzle body or the nozzle tip. Use of these tools can cause a small reduction of orifice size, and this will cause a large reduction in engine horsepower. Too much use of a wire brush will also remove the coating that is on the fuel injection nozzle for protection.
Illustration 2 g00570038
Remove carbon with the 8S-2258 Brass Wire Brush which is included in the 8S-2245 Injector Cleaning Tool Group .Before the fuel injection nozzle can be tested, remove all loose carbon around the tip of the fuel injection nozzle. Use the 8S-2245 Injector Cleaning Tool Group to clean the fuel injection nozzle. Refer to Special Instruction, SEHS8627, "Use of 8S-2245 injection Nozzle Cleaning Tool Group " for more information.
Remove retaining nut (8) from the holder assembly (1). Remove the tip assembly of fuel injection nozzle (7). Wash the needle valve and the body.Note: Do not mix the needle valve and bodies of different nozzles. The components of the nozzle tip assembly are a precise fit. The components must not be exchanged with other components. Do not touch the sliding surfaces of the needle valve.
Wash tip assembly of fuel injection nozzle (7) in clean kerosene. After washing, assemble the needle valve and the body in clean fuel.
Tighten retaining nut (8) to a torque of 34 5 N m (25 4 lb ft).
Replace the nozzle tip if the discharge pattern is still unacceptable.Note: Extra care should be used in handling the fuel injection nozzle in order to prevent damage to the nozzle tip. A scratch or a burr could cause needle leakage or spray distortion. Dirt that is in the orifices of the nozzle tip can damage engine components. Dirt can also cause spray distortion.Fuel Injection Lines
Fuel from the fuel injection pump goes to the fuel injection nozzle through the fuel injection lines. When the fuel injection lines are disconnected or removed, always put caps or plugs on the ends of the lines in order to keep dirt out of the lines. Ensure that all of the line clamps and all of the vibration dampers are installed in the original locations when the fuel injection lines are installed.Note: Fuel injection lines can leak if the fuel injection lines are bent or damaged. Fuel injection lines can also leak if the fuel injection lines are rubbing. Leakage of fuel can also cause a fire. Replace any lines which have damage or leaks that can not be corrected when the nuts are tightened to the correct torque.Note: Ensure that the fuel injection line clamps are installed in the correct location. Incorrectly installed clamps may allow the fuel injection lines to vibrate. Incorrectly installed clamps may allow the fuel injection lines to become damaged. The damaged lines may leak. Leakage of fuel can cause a fire.All nuts that hold a fuel injection line to the fuel injection nozzle or to the fuel injection pump must be tightened to the correct torque. If the nut is loose, fuel will leak from the connection. If the nut is too tight, the inside diameter of the fuel line will become smaller. This causes a restriction to the flow of fuel in the fuel line. Use a torque wrench to tighten the nuts of the fuel injection lines to a torque of25 N m ( 18 lb ft).Pressure Test
Ensure that you wear eye protection at all times during testing. When fuel injection nozzles are tested, test fluids travel through the orifices of the nozzle tip with high pressure. Under this amount of pressure, the test fluid can pierce the skin and cause serious injury to the operator. Always keep the tip of the fuel injection nozzle pointed away from the operator and into the fuel collector and extension.