842196 Volvo.Penta Cap

start by:a) remove fuel injection pump housingb) remove governorc) remove service meterd) remove dash **This operation is in the POWER TRAIN DISASSEMBLY AND ASSEMBLY SECTION. 1. Remove cover (1). Remove the lock and nut (2). 2. Remove drive gear (3) with tool (A). 3. Fasten a hoist to fuel pump and governor drive (4). 4. Remove three bolts (5).5. Remove four bolts (6) and locks.6. Remove the fuel pump and governor drive. Weight of the fuel pump and governor drive is 50 lb. (22.7 kg).Install Fuel Pump And Governor Drive
1. Fasten a hoist to the fuel pump and governor drive (1). Put it in position on the timing gear cover. Install the bolts and locks that hold it. 2. Heat drive gear (2) to a maximum temperature of 450°F (232°C). Install the drive gear on the shaft as shown. 3. Install the lock and nut (3). Tighten the nut to a torque of 325 25 lb. ft. (440.6 33.9 N m).4. Check the end play of the shaft with tool (A). The end play of the drive shaft must be .008 to .012 in. (0.2 to 0.3 mm). 5. Install cover (4) and the bolts that hold it.end by:a) install service meterb) install dash *c) install fuel injection pump housingd) install governor*This operation is in the POWER TRAIN DISASSEMBLY AND ASSEMBLY SECTION.Disassemble Fuel Pump And Governor Drive
start by: a) remove fuel pump and governor drive 1. Remove bolts (1) that hold cover (2) in position. Remove the cover and gasket.2. Remove bolts (3). Remove cover (5) and the gasket.3. Remove bolts (6). Remove cover (4) and the gasket. 4. Remove coupling assembly (7) from the pinion assembly. 5. Remove three bolts (8) and locks from the pinion assembly. 6. Remove pinion assembly (9) and the washer from the housing assembly. 7. Put tool (B) around the bottom of the pinion assembly as shown.8. Use tool (A) and an arbor press to remove the pinion from the pinion assembly.
Make sure tool (B) is not in the way of the pinion when it is pushed out of the pinion assembly.
9. Remove washer (10) and washer (11) from the pinion assembly.
Put identification on the washers as to their location in the pinion assembly.
10. Remove shaft assembly (12) from the housing assembly. 11. Remove three bolts (13) and locks.12. Remove cage assembly (14) from the housing assembly. 13. Remove three bolts (15) and locks.14. Remove washer (16) and the thrust washer from the cage. 15. Remove two bearings (17) from the cage. 16. Remove gear (18) and the coupling from the shaft assembly. 17. Remove four bolts (19) and two locks from the gear and coupling. Remove the gear and coupling. 18. Remove four bolts (20) and locks. Remove shaft (22) from shaft assembly (21).Assemble Fuel Pump And Governor Drive
1. Put shaft (2) in shaft assembly (1). Install the four bolts and locks that hold them together. Tighten the bolts to a torque of 60 lb. ft. (81.3 N m). 2. Install gear (3) in coupling (4). Install the four bolts and locks that hold them together. 3. Put the gear and coupling in position over the shaft assembly as shown. 4. Install the two bearings in the cage (5) with tool (A). Install the bearings even with the outside surface of the cage. 5. Put thrust washer (7) in position on the cage. Put the curved (concave) surface toward the inside of the cage.6. Put washer (6) in position on the cage. Install the three bolts and locks that hold the cage assembly together. 7. Put cage assembly (8) in position in the housing assembly. Install the three bolts (9) and locks that hold it. 8. Install the shaft assembly in the housing assembly as shown. 9. Put washer (11) in position on bearing (12) as shown. Install pinion (10) with an arbor press until it makes contact with the washer. 10. Turn the bearing and pinion over. Install washer (13) with an arbor press and a 15/16 in. (23.81 mm) socket. Install the washer until the end play between the bearing (12) and washer (11) is .002 to .004 in. (0.05 to 0.10 mm). Check the end play with a feeler gauge. The pinion must turn freely after it is installed in the pinion assembly. 11. Install the washer and pinion assembly (14) in the housing assembly. Install the bolts and locks that hold it. 12. Install coupling assembly (15) in the pinion assembly. 13. Install covers (16) and (18) on the housing assembly.14. Install cover (17) on the housing assembly.end by: a) install fuel pump and governor drive