How to Change Fuel Feed Pump

Fuel Feed Pump, Change

TAD550GE, TAD551GE, TAD750GE, TAD751GE

Removal

1 Remove the fuel pump and coolant pump drive belt; refer to Drive Belt, Change page 204.

IMPORTANT!

Work on the fuel system demands exceptional cleanliness.

NOTICE! Be prepared to gather up fluids.

2 Undo clamp (1) and remove the fuel line (2).

3 Undo (1) the bracket (2).

4 Remove the fuel feed pump (2) from the bracket.

Installation

5 Attach (1) the new fuel feed pump (2). Tightening torque: 20 Nm (14.8 lbf. ft.)

6 Install in reverse order.

7 Install the fuel pump and coolant pump drive belt; refer to Drive Belt, Change page 204.

8 Warm up the Volvo engine and perform a function check with regard to any leakages.

Fuel Feed Pump, Change

TAD752GE, TAD753GE, TAD754GE

Removal

IMPORTANT!

Work on the fuel system demands exceptional cleanliness.

NOTICE! Be prepared to gather up fluids.

1 Undo the fuel line clamp.

2 Remove the fuel pipes (1) between the fuel feed pump and the fuel pre-filter.

3 Remove the return fuel line (2).

4 Remove the fuel pipe (3) from the fuel feed pump.

5 Remove the fuel feed pimp and O-ring. Tightening torque: 21 Nm (15.5 lbf. ft.)

Installation

6 Install in reverse order.

7 Vent the fuel system; refer to Fuel system, bleeding

page 104.

8 Warm up the engine and perform a function check with regard to any leakages.

23-7 Injectors and Delivery Pipes

Injector, Change

TAD550GE, TAD551GE, TAD750GE, TAD751GE

Tools:

9998511 Lever

88800070 Wrench

Removal

IMPORTANT!

Work on the fuel system demands exceptional cleanliness.

NOTICE! The main switch must be in the off position before work is begun.

NOTICE! Be prepared to gather up fluids.

1 Remove the protective cover.

2 Cut the harness cable ties.

IMPORTANT!

Install protective plugs in open connections.

3 Remove and scrap the delivery pipe.

4 Plug connections to exclude dirt.

5 Disconnect the wiring (1) from the injectors.

6 Remove:

retaining bracket bolt (1).

retaining bracket (2).

NOTICE! Make sure that leak-off fuel does not leak into the cylinders.

NOTICE! Mark up installation sequence if more injectors

are removed.

7 Remove the injector (1) and the seal washer (2). If necessary use 9998511 Lever.

NOTICE! The rail unit may need to be removed for cylinders 1-5; refer to 23-7, Common Rail,

Change.

8. Remove the O-ring

Installation

NOTICE! Use new components.

• O-ring.

• Seal washer.

9 Brush a thin coating of oil around the new O-ring.

IMPORTANT!

Carefully wipe away combustion residue from cylinderhead orifices before installing the injectors. Vacuum dirt particles away.

NOTICE! The retaining brackets must be installed together with the injectors on cylinder 1-5.

NOTICE! Do not press directly on the connector bolts, but on the plastic between them.

10 Install the injectors carefully. Note the angle of the injector fuel connection.

NOTICE! Tightening sequence.

11 Injector retaining bracket: First tighten by hand. Tightening torque: 4 Nm (3.0 lbf. ft.)

IMPORTANT!

Delivery pipes must always be replaced with new ones after removal.

12 Install a new delivery pipe (1) between the injector and the rail unit.

• Check and adjust to the correct position.

• First tighten by hand.

Tightening torque: 4 Nm (3.0 lbf. ft.)

13 Fasten the retaining bracket.

Tightening torque: 20 Nm (14.8 lbf. ft.)

14 Fasten the fuel pipe. Use 88800070 Wrench.

Tightening torque: 25 Nm (18.4 lbf. ft.)

15 Connect the electrical wiring (1) to the injectors. Tightening torque: 1.5 Nm (1.1 lbf. ft.)

16 Install the protective cover. Tightening torque: 10 Nm (7.4 lbf. ft.)

17 Secure the harness with cable ties.

18 Reconnect batteries if necessary.

19 Vent the fuel system; refer to Fuel system, bleeding page 104.

Injector, Change

TAD752GE, TAD753GE, TAD754GE

Tools:

885510 Plugs

9996400 Slide hammer

9998007 Adapter

88800070 Wrench

Removal

NOTICE! The main switch must be in the off position before work is begun.

1 Remove the oil trap.

2 Remove the valve cover.

IMPORTANT!

Work on the fuel system demands exceptional cleanliness.

NOTICE! Be prepared to gather up fluids.

3 Remove the hollow screw from the return line on the cylinder head.

4 Disconnect the wiring from the injectors.

IMPORTANT!

The components pipes may not be re-used.

5 Remove and scrap the delivery pipes (1).

6 Remove the injector delivery pipe nuts (2) from the union    s (3).

7 Remove the injector delivery pipes by carefully tapping out the pies with the aid of 9996400 Slide hammer and 9998007 Adapter.

8 Remove the injector bolts.

9 Remove the injectors.

NOTICE! Make sure the sealing washers are also removed.

10 Use an 8-9 mm drift in the yoke and prize the injector away.

11 Plug the hole using 885510 Plugs.

Installation

IMPORTANT!

Carefully wipe away combustion residue from cylinderhead orifices before installing the injectors. Vacuum dirt particles away.

NOTICE! Use new components.

12 Note the position of the washer; the conical part

(1) faces the injector.

13 Position the injector so that the installation hole

(1) faces the fuel pump side. 

14 Lightly oil the O-ring.

15 Install the new injectors.

NOTICE! Do not press directly on the connector bolts, but on the plastic between them.

16 Install bolt (1) in the injector yoke. Tightening torque: 4 Nm (3.0 lbf. ft.) Then loosen the bolt (1) somewhat.

NOTICE! Use new components. O-ring and injector delivery pipe.

17 Lubricate and install the O-ring.

18 Align the injector delivery pipe and press it into the holder so that the balls (1) align with the grooves (2) in the holder.

19 Pre install the connection bolt (1).

Tightening torque: 20 Nm (14.8 lbf. ft.)

20 Tighten the bolt (1).

Tightening torque: 23 Nm (17.0 lbf. ft.)

21 Connect the electrical wiring (2) to the injectors.

Tightening torque: 1.5 Nm (1.1 lbf. ft.)

22 Re-tighten the connection bolt (1).

Tightening torque: 52 Nm (38.4 lbf. ft.)

IMPORTANT!

Delivery pipes must always be replaced with new ones after removal.

23 Install the delivery pipes (1). Use 88800070 Wrench Tightening torque: 25 Nm (18.4 lbf. ft.)

24 Check the valve cover gasket and replace as necessary.

25 Install the valve cover.

Tightening torque: 8.5 Nm (6.3 lbf. ft.)

26 Install the hollow screw from the return line on the cylinder head.

27 Install the oil trap. Check and replace the O-ring

as necessary. Tightening torque: 20 Nm (14.8 lbf. ft.)

28 Reconnect batteries if necessary.

29 Vent the fuel system; refer to Fuel system, bleeding page 104.