Service Bulletin Volvo Penta of the Americas 1300 Volvo Penta Drive Chesapeake, Virginia 23320-9810 USA
Group
Number
Version
23-3
7
01
High pressure fuel pump Models All Fuel Cell equipped EFI Gasoline Engines
Distribution: M
Date: 01-2004
Binder: C
Page: 1(1)
High Pressure Fuel Pump
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Volvo Penta has introduced a High Pressure Fuel Pump Replacement Kit PN 3588865. Use the instructions included in the kit when servicing the fuel cell. This kit is to be used if the high pressure fuel pump needs replacement on Fuel Cell PN 3861355 and PN 3860210. In cases where only the high pressure pump needs to be replaced, this will allow for a faster and more cost effective repair. In cases where a problem exists in the low pressure fuel pump, or the reservoir portion of the fuel cell, the entire fuel cell will still require replacement. Testing at the low pressure test fitting at the base of the fuel cell, and the high pressure test fitting on the fuel rail, will easily isolate whether the low pressure or high pressure fuel pump has failed. Volvo Penta Fuel Pressure Test Kit P/N 3855533 includes both the low pressure fitting adapter ( PN 3855354 ) and the high pressure fitting adapter ( PN 3862357 ) required to perform these tests. Also, unplugging the electrical connector on each fuel pump one at a time and cycling the key to the "on" position, can assist in confirming a suspected seized fuel pump.
See the chart below for fuel pressure values: Engines using Fuel Cell P/N 3861355 or P/N 3860210 Model
Low pressure
High Pressure
4.3 TBI
8 psi +/- 4psi
29 psi +/- 2psi
5.0 TBI
8 psi +/- 4psi
29 psi +/- 2psi
5.7 TBI
8 psi +/- 4psi
29 psi +/- 2psi
4.3 PFI
8 psi +/- 4psi
50-60 psi
5.0 PFI
8 psi +/- 4psi
50-60 psi
5.7 PFI
8 psi +/- 4psi
50-60 psi
7.4 PFI
8 psi +/- 4psi
36-44 psi
8.1 PFI
8 psi +/- 4psi
36-44 psi
Note: This High Pressure Fuel Pump Kit is used only on Fuel Cell PN 3861355 and PN 3860210. It does not apply to earlier models using the Vapor Separator style system. Warning! Follow all related safety procedures as noted in the Workshop Manual during all fuel system testing procedures.
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