862991 Volvo.Penta Cable

1. Remove the cotter pin, pin (1) and disconnect the governor rotochamber linkage from the governor control lever.2. Remove plug (2) from the fuel injection pump housing. 3. Install tool (A) in the fuel pump housing as shown with the square end down. Use a small amount of hand force to push down on tool (A) while the control lever is moved forward to the "FUEL ON" position. Rack travel will stop in the center (zero) position. Hold a light forward force on the governor control lever to keep the fuel racks in the center (zero) position. 4. Disconnect fuel line (4) from the fuel pump. Put caps or plugs in all fuel line openings to keep dirt out of the fuel system.5. Remove felt washer (3) from the fuel injection pump housing. 6. Use tool (B) to remove bushing (5) from the fuel injection pump housing. 7. Use tool (C) to remove the fuel injection pump.
When injection pumps, spacers and lifters are removed from the injection pump housing, keep the parts of each pump together so they can be installed in their original location.
Be careful when the fuel injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. The check assemblies are made as a set. Do not mix the parts of the different check assemblies. Do not remove or make any adjustments of the gear segment on the plunger. It has been preset at the factory. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
8. Disassemble the fuel injection pump as follows: Remove ring (6). Make a separation of bonnet (7) from barrel (8). Remove the spring and the check assembly from the bonnet. Remove plunger (9), the washer and spring from barrel (8). 9. Remove spacer (10) from the fuel injection pump housing. Make a note of the position from which each spacer was removed so each spacer can be installed in its original position.Install Fuel Injection Pumps
1. Inspect all parts for wear or damage and make a replacement if necessary. 2. Put plunger (5), washer (6) and spring (4) in position on barrel (9). Put check valve assembly (3) and spring (8) in position in bonnet (7). Connect bonnet (7) and barrel (9) together with ring (2). Keep O-ring seal (1) with the bonnet for use at installation. 3. Put spacer (12) into position in the pump housing bore. Make sure the correct spacer is with each pump.4. Make an alignment of slot (15) in gear segment (10) with groove (14) in the barrel.5. Use tool (A) to put the rack in the center (zero) position. See Remove Fuel Injection Pumps.6. Put the fuel injection pump straight down into the housing with tool (B). Make sure slot (15) in gear segment (10) is in alignment with pin (11) in the lifter and groove (14) is in alignment with dowel (13) in the housing. Install the fuel injection pump. 7. Make sure O-ring seal (1) is in position as shown. 8. Install bushing (16) in the fuel injection pump housing bore. If the pump is in the correct position, bushing (16) can be installed with fingers until it is even with the outside surface of the housing. If the bushing can not be installed as described above, remove the fuel injection pump, and repeat Steps 4 through 6. Tighten bushing (16) to a torque of 203 14 N m (150 10 lb.ft.).9. Install felt washer (17) in the fuel injection pump housing. 10. Connect fuel lines (18) to the fuel injection pump. Tighten the fuel lines to a torque of 41 7 N m (30 5 lb.ft.).11. Check the correct installation of the fuel injection pumps with the engine stopped. See Fuel Rack Travel.
If one or more of the injection pumps have been installed wrong, damage to the engine is possible if cautions are not taken when the engine is first started. Make preparation to close off the air intake to stop the engine if necessary.
12. Connect the governor rotochamber linkage to the governor control lever with pin (19) and the cotter pin.13. Remove tool (A) and install the plug into the fuel injection pump housing.