Volvo Penta 2003 Injector Sleeve install

[wilson740]

Volvo Penta 2003 Injector Sleeve install

I am replacing injector sleeves and am unable to locate the flaring tool for the sleeves. Any recommendation where to find one or a work-around. Thanks!

[wilson740]

I contacted a local Volvo Penta service center. They went out of their way to look at their online up to date repair instruction and we discovered there is a typo in the service manual the general public has access to via google.

The correct part number is 884823. Injector sleeve flaring tool Volvo Penta 2000 series.

[DougR]

Yes, in the three different printed manual versions that I have, 1984, 1986, and 1997, two of the three show the transposed number (884283 vs 884823) in the pictorial text, however on the page listing all the service tools all three versions show the correct number.(884823)

It might be noted that there are two tools listed for installing the injector copper:
- 884557- drift for installing the copper sleeve in the head
- 884823- flaring tool for swedging the copper into the head

According to the online store “Marine Parts Express” the swedging tool does not show up discontinued.

[MKESailor]

I know this is an old post but.... I am currently in the process of installing new cups. The first shot at it the flaring tool broke. Did you hace success flairing the cups?

[Engine man]

I have the copper injector sleeve installation tools for the MD6, MD7, MD11, MD17 Volvo engines, and other specialized Volvo tools. I don't know If these tools are correct for the 2000 engine series. Joe

Originally Posted by wilson740

I contacted a local Volvo Penta service center. They went out of their way to look at their online up to date repair instruction and we discovered there is a typo in the service manual the general public has access to via google.

The correct part number is 884823. Injector sleeve flaring tool Volvo Penta 2000 series.

[Tcubed66]

I would think after 2 years old (this post) is that his request is satisfied. If not I do have the tools to do it for rent CONUS with sufficient deposit.

[MKESailor]

I work for a boat yard in Wisconsin. We ordered the sleeves and the flair tool from volvo. First try the flair tool boke. Tech followed all the instructions in the manual. We ordered another flair tool and it started to fail as well. Woul love to have a conversation with someone that has succeffully flaired the sleeves.

[DougR]

There is a good bit of load on the tool when flaring the copper tip, and I have seen the “dowel”, as VP calls it, or swedge twisted a good bit, or even destroyed.

First it’s important to make sure that the copper is seated all the way down in the head with drift 884557.

Then grease up the “dowel” with a good dollop of grease or Never Seize, thread the dowel back into the tool, and clamp the tool in place with the injector clamp. Then screw the dowel/ swedge down into the copper and expand the copper.

Finally, file flat any copper extending more than 1 mm beyond the surface of the head. Failing to file the copper down might cause the injector spray to interfere with the copper.

Doing this I have been successful. However maybe there is a problem with the tools......

[lucasb]

I had the same issue with my 2002 engine , the inj. sleeves are the same and no tools were available. I made one and installed the sleeves successfully. The cost was around 50 euros. If you need a drawing of the tool I made I'll be happy to share it.
Lucas

[MKESailor]

Please do share!
You can email me: jrice9310@gmail.com

[Russian007]

Originally Posted by lucasb

I had the same issue with my 2002 engine , the inj. sleeves are the same and no tools were available. I made one and installed the sleeves successfully. The cost was around 50 euros. If you need a drawing of the tool I made I'll be happy to share it.
Lucas

If possible I could use one too.
brian90402@gmail

[Dantp]

Originally Posted by lucasb

I had the same issue with my 2002 engine , the inj. sleeves are the same and no tools were available. I made one and installed the sleeves successfully. The cost was around 50 euros. If you need a drawing of the tool I made I'll be happy to share it.
Lucas

Could you send it me as well. I've (tried) to pm you with my email.

Dan

[lucasb]

Hope this helped gents.It took me 1 hour to make this tool.
Lucas

[lucasb]

some more

[lucasb]

And here is the real tool