Injector Sleeve Kit – Fits Volvo Penta AD31 AD41 KAD42 KAD43 TAMD31 TAMD41 TAMD42 (Replaces 838609, 861255)

Product Details

This Injector Sleeve Kit is precision-engineered for Volvo Penta AD31, AD41, KAD42, KAD43, TAMD31, TAMD41, and TAMD42 series engines. Designed to restore proper injector seating and prevent fuel leaks, this kit delivers reliable fitment across dozens of 31, 41, 42, and 43 model variants, including earlier versions.

Serves as a direct aftermarket replacement for Volvo Penta part numbers 838609, 861255, and ORB11609.

• 68 mm length, 22 mm diameter for exact OEM-spec fit
• Compatible with both naturally aspirated and turbocharged models
• Ideal for routine injector service or complete rebuild procedures

Part Number Matrix

Use this matrix to confirm equivalent references across OEM and aftermarket.

Engine & Model Compatibility

Confirm your engine model/year in the table below.

Technical Specs

Length

68 mm

Diameter

22 mm

Material

OEM-specification copper alloy

Application

Injector sealing & alignment

What's in the Box

• Injector Sleeve Kit (quantity and components as required for installation)

Installation Notes

1. Disconnect battery negative terminal and relieve fuel system pressure before beginning work.
2. Remove injector lines, fuel return hoses, and any obstructing components to access the injectors.
3. Carefully extract the old injector; if the sleeve remains in the head, use a slide-hammer or extractor tool designed for sleeves.
4. Clean the injector bore thoroughly to remove carbon deposits, old sealant, and debris.
5. Inspect the bore for cracks or scoring; address any damage before proceeding.
6. Lightly lubricate the new sleeve's outer diameter with clean engine oil to ease installation.
7. Install the new sleeve squarely into the bore, ensuring it seats fully to the shoulder or specified depth.
8. Insert the injector, torque to Volvo Penta specification, and reconnect fuel lines using new copper washers.
9. Prime the fuel system, bleed air from injector lines, and check for leaks before starting the engine.
10. Run the engine at idle and inspect all connections; verify smooth operation and absence of smoke or fuel odor.

Troubleshooting & FAQ

How do I know if my injector sleeve needs replacement?

Common signs include fuel odor around the injector, visible external leaks, hard starting, white or black exhaust smoke, and poor idle quality. Sleeves can corrode or crack over time, allowing combustion gases or coolant into the injector bore.

Can I reuse the old sleeve?

No. Once removed, sleeves often deform or lose their sealing surface. Always install a new sleeve to ensure proper seating and prevent future leaks.

Do I need special tools to install this sleeve?

A slide-hammer extractor is recommended for removing old sleeves. Installation typically requires a driver or socket that matches the sleeve diameter, plus a torque wrench for injector bolts. Always consult your engine's service manual for specific tooling and torque values.

Will this fit both earlier and current versions of my engine?

Yes. This kit covers earlier-version models (marked with *) as well as standard production variants across the AD31, AD41, KAD42, KAD43, TAMD31, TAMD41, and TAMD42 families. Verify your model code against the compatibility table above.

What's the difference between this and the original Volvo Penta sleeve?

This aftermarket sleeve is manufactured to the same dimensional and material specifications as OEM parts 838609 and 861255. It provides equivalent sealing, heat resistance, and durability at a more economical price point.

How often should injector sleeves be replaced?

Replace sleeves whenever injectors are serviced or if leaks, corrosion, or bore damage is detected. There is no fixed interval, but inspect during major overhauls or every 2,000–3,000 operating hours in high-duty applications.

OEM vs. Aftermarket?

This listing is an aftermarket replacement (not OEM). Built to OEM-level specifications with comparable materials. Manufactured in an ISO 9002 facility, batch-inspected for consistency.

Shipping speed & cost

We ship worldwide quickly—typical transit 5–15 days. Standard shipping is free; expedited options appear at checkout where available.

Warranty & returns

Covered by a 1-year warranty against manufacturing defects under normal use. If issues arise, contact support with your order details. Returns are accepted within our standard window (unused & in original condition). See our policy page or reach out for instructions.

Safety & Important Info

• Verify images/specifications against your original part. If anything differs—even if your model appears compatible—do not purchase.
• This is an aftermarket replacement, not an OEM component.
• Professional installation is recommended for safety and performance.

About Sea Sierra

• Pro-Grade Standards — We supply marine parts engineered to OEM-level tolerances and tested for real-world conditions.
• Fast Global Fulfillment — Free standard delivery to most regions in 5–15 days.
• Manufacturer-Direct Value — Fair pricing without compromising on materials or QC.