Volvo Penta 2002 - Val Ve Spr I Ngs; Rocker Ar M M Ec Hani S M; I Nj Ect or S

Repl aci ng t he val ve seat exhaust por t 2003T
Gr i nd down t he val ve di sc of a di scar ded val ve t o j ust bel ow
27 mm ( 1 . 063
i n)
di amet er
. Push t he val ve st em t hr ough t he
gui de . NOTE! Do not push i n t oo f ar - t he val ve di sc shoul d be
j ust bel ow t he edge of t he seat . Spot
wel d t he di sc i n pl ace at
t hr ee poi nt s usi ng a el ect r i c wel der . Knockout t he seat by
hi t t i ng t he val ve gui de
wi t h a pl ast i c- headed hammer .
Cool t he
new
seat
t o appr ox . - 20° C ( - 4° F) ; t he cyl i nder
head shoul d beat r oom t emper at ur e ( + 20° 0168° F)
.
Pl ace t he
cool ed seat on t ool
884961- 4 and knock i t down unt i l i t
bot t oms. NOTE! Tur n t he seat wi t h t he val ve f ace
t owar ds
t he
t ool
.
Val ve spr i ngs
5 . Checkt he f r ee l engt h of
t he val ve spr i ngs and t he l engt h
when l oaded .
L = Lengt h, unl oaded
42, 5 mm ( 1 . 67323 i n . )
L 1 = Lengt h, l oaded wi t h 170±10 N ( 17±1 kp) 32
mm
( 1 . 25984
i n . )
L 2 = Lengt h, l oaded wi t h 300±20 N ( 30±3 kp) 24
mm
( 0 . 94488 i n . )
Rocker ar m mechani sm
6 .
Di sassembl e t he r ocker ar m mechani sm and cl ean t he
par t s . Check t he wear of t he shaf t and r ocker ar m bush i ngs .
Shoul d t he bushi ngs need t o be r epl aced, uset he mandr el
p/ n
9991867 f or t he r emoval and i nst al l at i on, ( make
sur e
t hat t he oi l hol e i n t he bushi ng coi nci des wi t h t he one i n t he
r ocker ar m) .
Af t er t he
i nst al l at i on t he bushi ngs
ar e r eamed
t o a cl ose r unni ng f i t . When i nst al l i ng t he r ocker ar m shaf t ,
i t must be t ur ned so t hat t he l ubr i cat i on hol es ar e f aci ng t he
val ve- si de
. Check t o make sur e t hat t he r ocker ar m cont act
sur f ace agai nst t he val ve i s concave . Mi nor adj ust ment s ar e
made i n
a
val ve gr i ndi ng
machi ne . Oi l t he shaf t and i nst al l
t he par t s .
Pr essur e t est i ng t he nozzl es
7 . Check t he nozzl e' s spr ay pat t er n at t he cor r ect openi ng
pr essur e ( see Techni cal Dat a) .
Check al so t hat t he f uel spr ays
st op
si mul t aneousl y and no dr i ppi ng occur s .
Adj ust t he openi ng- pr essur e
wi t h adj ust ment - washer s ( 1)
bei ng avai l abl e
i n di f f er ent t hi cknesses f r om 1 mm U3937
i n . ) t o 1, 95 mm ( . 076772 i n . ) i n st eps
of 0, 05 mm ( . 001969
i n . ) . Di sassembl e
t he i nj ect or and r epl ace t he adj ust ment - washer
agai nstat hi nneroneorat hi ckeronedependi ngon
whet her
t he pr essur e must be r educed or i ncr eased .
Assembl e
t he i nj ect or and check t he openi ng- pr essur e and
t he spr ay- pat t er n .
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