3802121 Volvo.Penta Turbocharger

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     422-7170     Capping Kit     1    
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.
Illustration 1 g02689876
Make temporary identification marks on tube assembly and hose assembly in order to show the correct position.
Place a suitable container below the primary fuel filter in order to catch any fuel that might be spilled.
Disconnect hose assembly (6) from primary fuel filter (2) .
Use Tooling (A) to plug the connection on primary fuel filter base (2) .
Use Tooling (A) to cap hose assembly (6) .
Remove banjo bolt (4) and sealing washers (3) (not shown).
Use Tooling (A) to cap tube assembly (5) .
Use Tooling (A) to plug primary fuel filter base (2) .
Remove bolts (1) and remove primary fuel filter (2) from the mounting bracket for the primary fuel filter.
Illustration 2 g02689916
If necessary, remove the mounting bracket for the primary fuel filter from the cylinder head. Follow Step 3.a through Step 3.c in order to remove the mounting bracket for the primary fuel filter.
Remove bolt (7) and bolts (9) from primary fuel filter mounting bracket (10) .
Remove mounting bracket (12) from cylinder head (8) .
Illustration 3 g02689915
If necessary, follow Step 12.a through Step 12.d in order to disassemble primary fuel filter (2) .
Remove plug (11) and remove sealing washer (12) . Use Tooling (A) to plug primary fuel filter base (2) .
Remove connection (16) and remove seal washer (16) . Use Tooling (A) to plug primary fuel filter base (2) . Use Tooling (A) to cap connection (16) .
Remove plugs (13) and remove sealing washers (14) . Use Tooling (A) to plug primary fuel filter base (2) .
Remove fuel filter element (17) . Refer to Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element - Replace" for the correct procedure.Installation Procedure
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.
Ensure that the primary fuel filter base is clean and free from damage. If necessary, replace the complete primary fuel filter base and filter assembly.
Illustration 4 g02689915
If necessary, follow Step 2.a through Step 2.d in order to assemble primary fuel filter (2) .
Install a new sealing washer (12) to plug (11) . Install plug (11) to primary fuel filter (2) . Tighten the plug to a torque of 23 N m (204 lb in).
Install a new sealing washer (15) to connection (16) . Install connection (16) to primary fuel filter (2) . Tighten the connection to a torque of 23 N m (204 lb in).
Install new sealing washers (14) to plugs (13) . Install plugs (13) to primary fuel filter (2) . Tighten the plugs to a torque of 23 N m (204 lb in).
Install a new filter element (17) . Refer to Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element - Replace" for the correct procedure.
Illustration 5 g02689916
If necessary, install the mounting bracket for the primary fuel filter to the cylinder head. Follow Step 3.a through Step 3.c in order to install the mounting bracket for the primary fuel filter.
Position primary fuel filter mounting bracket (10) onto cylinder head (8) .
Install bolt (7) and bolts (9) to primary fuel filter mounting bracket (9) .
Tighten bolt (7) to a torque of 44 N m (32 lb ft).Tighten bolts (9) to a torque of 22 N m (195 lb in).
Illustration 6 g02689876
Position the assembly of primary fuel filter (2) onto the primary fuel filter mounting bracket.