Volvo Penta — Fuel Injector Testing and Adjustment
A Volvo Penta service procedure — check it applies to your exact model before use.
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Before you start
- Use only clean test oil that meets ISO 4113 or clean diesel to test the injector
- Be very careful when working with the fuel injector nozzle. The fuel pressure jet can penetrate deep into the skin tissue and cause blood poisoning
Procedure
- Take off the cap nut and remove all parts.
- Wash the details in an ultrasonic cleaner, alternatively washing petrol or Vanolen.
- Inspect the injector details, using an injector microscope.
- Dip the parts in oil before assembly.
- Connect the injector to the nozzle tester.
- Check the opening pressure.
- Check the density after the injector has opened.
- Set the pressure by selecting an appropriate shim. Tighten the cap nut to 40 ±5 Nm.
- Check the seal by pressing down the tester handle until you obtain a pressure of around 2.0 MPa below the previously measured opening pressure.
- If no leaks appear within 10 seconds the nozzle is sealed.
- If the nozzle is leaking, dismantle and clean the injector to prevent it from leaking. If the nozzle still is leaking, replace the injector.
- Perform chatter characteristic and spray pattern tests.
Tools required
- Nozzle tester
- Injector microscope
- Ultrasonic cleaner
Specs & torque values
- Opening pressure (per Technical data)
- Shim thickness adjustable
Source: manual:Volvo Penta Workshop Manual (Group 20-26) Product Code 7740922 2007 EN.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.