838609 861255 Injector Sleeve Kit for Volvo Penta AD31 AD41 AD42 AD43 TAMD31 TAMD41 TAMD42 TMD31 TMD41 KAD42 KAD43 KAMD42 KAMD43 | JLM Marine

Injector Sleeve Kit for Volvo Penta AD31 AD41 AD42 AD43 TAMD31 TAMD41 TAMD42 TMD31 TMD41 KAD42 KAD43 KAMD42 KAMD43

This Injector Sleeve Kit is designed for a wide range of Volvo Penta diesel engines, including the AD31, AD41, AD42, AD43, TAMD31, TAMD41, TAMD42, TMD31, TMD41, KAD42, KAD43, KAMD42, and KAMD43 series. Engineered to meet OEM specifications, this kit ensures reliable fuel injector sealing and optimal engine performance.

This aftermarket kit directly replaces Volvo Penta part numbers 838609 and 861255, as well as ORB 11609, providing a cost-effective solution without compromising quality.

• Precision-engineered dimensions: 68 mm length × 22 mm diameter
• Compatible with both earlier and current Volvo Penta diesel engine versions
• Direct-fit replacement for quick, straightforward installation

Part Number Cross-Reference

Use this table to confirm equivalent part numbers across OEM and aftermarket brands.

Compatible Engine Models

Confirm your engine model/year in the table below.

* = Earlier version

Technical Specifications

Package Contents

The package includes the following components:

• Injector Sleeve Kit (as shown in product images)

Installation Guide

1. Disconnect the battery and relieve fuel system pressure before beginning work. Ensure the engine is cool.
2. Remove the fuel injector from the cylinder head according to your engine service manual. Clean the injector bore thoroughly.
3. Inspect the old injector sleeve for wear, corrosion, or damage. Remove it carefully using the appropriate extraction tool.
4. Clean the injector sleeve bore in the cylinder head, ensuring no debris or carbon deposits remain. Use a suitable solvent and compressed air.
5. Measure the new injector sleeve to confirm dimensions (68 mm length, 22 mm diameter) match specifications.
6. Lubricate the outside of the new sleeve lightly with clean engine oil or assembly lubricant to ease installation.
7. Insert the new injector sleeve into the bore, ensuring it is seated squarely and fully. Use a sleeve installation tool if available to avoid damage.
8. Verify the sleeve is flush with the cylinder head surface or positioned per the manufacturer's specifications.
9. Reinstall the fuel injector, applying new copper washers or seals as required by your service manual.
10. Torque the injector hold-down clamp or retaining bolt to the specified value in your engine manual.
11. Reconnect fuel lines and bleed air from the fuel system according to Volvo Penta procedures.
12. Reconnect the battery, start the engine, and inspect for fuel leaks around the injector sleeve area. Allow the engine to reach operating temperature and recheck.

Troubleshooting & FAQ

Q: How do I confirm this injector sleeve kit fits my Volvo Penta engine?
A: Cross-reference your engine model with the compatibility table above and verify your current part number matches 838609 or 861255. Confirm that the sleeve dimensions (68 mm length, 22 mm diameter) match your original component.

Q: What are the signs that my injector sleeve needs replacement?
A: Common symptoms include fuel leaks around the injector, rough idling, loss of power, excessive smoke, or coolant contamination in the fuel system. Corroded or cracked sleeves often cause these issues.

Q: How often should I replace the injector sleeves?
A: Injector sleeves should be inspected and replaced whenever injectors are removed for service or replacement. If you notice fuel leaks, corrosion, or difficulty seating injectors, replacement is recommended immediately.

Q: Can I install this sleeve without special tools?
A: While basic hand tools may work, a proper injector sleeve removal and installation tool set is highly recommended to prevent damage to the cylinder head and ensure correct seating and alignment.

Q: OEM vs. Aftermarket?
A: This listing is an aftermarket replacement part (not an OEM component). We build to OEM specifications using comparable-grade materials. Production is done in an ISO9002-certified facility, and each batch is inspected for consistent performance.

Q: How fast do you ship and how much does it cost?
A: We offer fast global shipping—typically 5–15 days worldwide—and standard shipping is free. Expedited options are available at checkout depending on your location.

Q: What is your warranty and return policy?
A: This product includes a 1-year warranty against manufacturing defects under normal use. If something goes wrong, contact our support team with your order details. Returns are accepted within our standard return window (unused & in original condition); please see our policy page or reach out for instructions.

Important Notes

• Verify that the product images and specifications match your original part. If discrepancies exist—even if your model is listed—do not proceed with the purchase.
• This product is an aftermarket replacement part and is not an OEM component.
• Professional installation is recommended to ensure safety and optimal performance.

Why Choose JLM MARINE?

• Quality Assured: As a trusted manufacturer for over 20 years, we supply top marine brands globally.
• Fast Global Shipping: Free delivery worldwide in 5–15 days.
• Direct from Manufacturer: Competitive pricing without compromising quality.