6210778 Volvo.Penta Brush set

START BY:a) remove fuel linesb) remove fuel transfer pump 1. Remove cotter pin and pin (2). Move cable assembly (1) from control lever. Remove clip (4) from governor plate that fastens hose assembly in position.2. Disconnect shutoff solenoid wiring (3) at electrical connectors. 3. Put identification on hose assemblies (5) and (7) for assembly purposes. Disconnect hoses from the governor plate assembly.4. Disconnect hose assembly (6) from the fuel ratio control. 5. Remove bolts (8), washers, spacers and brackets (9) that fasten the fuel injection pump housing to the cylinder block. 6. Remove vee belts (11) from the fan drive and belt tightener.7. Disconnect spring (10) from belt tightener (12). 8. Remove cover (13) and gasket from the automatic timing advance housing.
Do not let retainer (15) drop in the housing.
9. Remove four bolts (14) and retainer (15) that hold the automatic timing advance to the fuel injection pump housing. 10. Install tooling (A) and a hoist to the governor plate as shown.11. Pull the fuel injection pump housing (16) out of the timing gear housing.12. Remove the fuel injection pump housing and governor from the engine. Weight of the unit is 50 kg (110 lb.). 13. Inspect two O-ring seals (18) on the bottom and O-ring seal (17) on the front of the fuel injection pump housing. Make a replacement if necessary.Install Fuel Injection Pump Housing And Governor
Make sure there is no paint, dirt or foreign material on the machined surface of the fuel injection pump housing and the machined surface of the cylinder block. The surfaces must be clean before the fuel injection pump housing is installed.
1. Remove the cover (1) and plug (2) from the flywheel housing and install tool (A). Turn tool (A) in a clockwise direction until the flywheel moves approximately 30°. 2. Turn tool (A) in a counterclockwise direction until timing bolt (3) can be installed in the flywheel. Use the following procedure to make sure the No. 1 cylinder is at top dead center (TDC) on the compression stroke. Remove the valve cover over the No. 1 cylinder. If the rocker arms for the intake and exhaust valves are free to move, the No. 1 cylinder is at top dead (TDC) on the compression stroke. Install the valve cover. 3. Remove the plug from the governor plate. Turn camshaft (4) until tool (B) (tapered end) can be installed in the groove (slot) in the camshaft. 4. Install O-ring seals (5) and (6) in the fuel injection pump housing. Put grease on seals (6) and engine oil on seal (5). 5. Put tooling (C) and a hoist on the fuel injection pump housing and put it in position on the cylinder block and the automatic timing advance housing. Make sure the camshaft in the fuel injection pump housing is in position in the automatic timing advance. 6. Install four bolts (9) that hold the fuel injection pump housing on the cylinder block.7. Put clean engine oil on the threads of the bolts that hold brackets (7) and (10) in the cylinder head. Tighten the bolts finger tight only.8. Tighten the bolts (8) that hold brackets (7) and (10) to the fuel injection pump housing to a torque of 45 7 N m (33 5 lb.ft.). Tighten the bolts that hold brackets (7) and (10) to the cylinder head to a torque of 45 7 N m (33 5 lb.ft.). 9. Install retainer (11) and bolts (12). Tighten bolts (12) to a torque of 27 N m (20 lb.ft.). Tighten bolts (12) again to a final torque of 136 7 N m (100 5 lb.ft.). 10. Install the gasket and cover (13).11. Remove timing bolt (A) from the flywheel housing and tool (B) from the fuel injection pump housing. Turn the flywheel two complete revolutions with tool (A) and install the timing bolt (3) in the flywheel housing and tool (B) in the fuel injection pump housing. If both the timing bolt (3) and tool (B) can be installed, the engine has the correct timing.12. If the timing bolt (3) and tool (B) can not be installed, repeat Steps 2, 3, 9 and 11. 13. Connect spring (14) on belt tightener (16). Install vee belts (15) on the fan drive and belt tightener. 14. Connect fuel lines (18) and (17) to the governor plate and fuel ratio control respectively. 15. Install hose clip (21) to governor plate. Connect shutoff solenoid connector (20) to the wiring harness.16. Install cable assembly (19) in position on control lever.END BY:a) install fuel transfer pumpb) install fuel lines