Volvo Penta — Replacing injector copper sleeve (cylinder head fitted)
Repair & overhaul
From a Volvo Penta service manual — check it applies to your exact model before use.
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Procedure
- Drain off the coolant (fresh-water system for marine engines).
- Remove the injector.
- Pull out the steel ring using puller 6419.
- Pull out the copper sleeve using puller 6657 (use 6372 if the extension has broken).
- Clean the sealing surface and turn the engine so that piston is at bottom dead centre.
- Oil-in a new O-ring in the cylinder head; push the sleeve and flaring tool into the head with the index mark upwards.
- Pull down the flaring tool until the sleeve bottoms, then press the flaring pin through the lower end.
- Tap the steel ring into place (gap 0.5 mm to the sleeve), fit the injector at 50 Nm and fill with coolant.
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Injector tightening torque 50 Nm (5 kpm = 37 lbf.ft.)
- Gap between steel ring and copper sleeve 0.5 mm (0.02 in)
Source: Volvo Penta service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.