849031 Volvo.Penta Cap

Start By:a. remove fuel injection linesb. remove belt tightener Put caps or plugs on all fuel system openings to keep dirt and other foreign material out of the fuel system. 1. Put alignment marks on the governor shaft and lever (1) for correct alignment during installation. Disconnect lever (1) from the governor.2. Disconnect fuel lines (2) and (4) from the fuel injection pump.3. Disconnect fuel lines (5) and (6) from the fuel transfer pump.4. Remove bolt (3) and plug (7) from the timing gear cover. 5. Loosen bolt (8) that holds the fuel pump drive gear to the fuel injection pump camshaft a maximum of one turn. 6. Remove three bolts (9).7. Loosen three nuts (10) that hold the fuel injection pump housing to the timing gear plate. Loosen the nuts until they are even with the end of the studs.
Tooling (A) must be installed in the position shown so the locks will not damage the wear passage in the timing gear cover.
8. Loosen the drive gear from the fuel injection pump camshaft with tooling (A) as follows:a. Install tooling (A) in the position shown, and tighten the locks to hold the tooling in place.b. Turn the extension counterclockwise to loosen the bolt in the fuel injection pump camshaft. As the bolt is loosened, it will push against tooling (A), and push the fuel injection pump camshaft out of the drive gear.c. Remove tooling (A) from the timing gear cover. Remove the bolt and washer from the fuel injection pump camshaft.9. Remove three nuts (10). See illustration B91140P1, and remove the fuel injection pump housing and governor from the engine. The weight of the fuel injection pump housing and governor is 22 kg (49 lb).Install Fuel Injection Pump Housing And Governor
1. Install the fuel injection pump housing and governor on tooling (A), or use a suitable vise to hold the unit.2. Remove bolts (2), cover (1) and the gasket from the fuel injection pump housing. 3. Install the bolt and washer used to hold the drive gear to fuel injection pump camshaft (3).4. Install tool (B) in the hole of the fuel injection pump housing. Turn fuel injection pump camshaft (3) until timing pin (B) engages in the notch in the fuel injection pump camshaft. Tool (B) will hold the fuel injection pump camshaft in the correct position to set the fuel injection timing of the engine. 5. Be sure O-ring seals (4) and (5) are in position on the governor and the fuel injection pump housing. 6. Put the fuel injection pump housing and governor in position on the engine, and install three nuts (7).7. Install three bolts (6). Bolt (8) must be tight enough to hold the gear clearance (backlash) out of the timing gears when the engine is turned. However, the timing gear must be able to turn on the shaft when the engine is turned to put the No. 1 piston on the top center compression position (TDC).8. Put clean oil on the threads of bolt (8). Install bolt (8) and the washer to hold the drive gear to the fuel injection pump camshaft. Tighten the bolt finger tight only. 9. Put No. 1 piston at the top center compression position (TDC) with the following procedure:a. Remove plug (9) from the flywheel housing. b. Turn the crankshaft clockwise (as seen from the front of the engine) until a 3/8 "-16 x 2 in. (50.8 mm) bolt (10) can be installed through the timing hole in the flywheel housing and into the hole in the flywheel. c. Remove the valve cover from the valve cover base. See Remove Valve Cover.d. Check to see if both rocker arms (11) for the No. 1 piston can be moved backward and forward by hand. The No. 1 piston is at the top center compression position when the bolt is installed in the flywheel, and both rocker arms for No. 1 piston can be moved backward and forward. If both rocker arms cannot be moved, the No. 1 piston is not at the top center compression position. Remove the bolt from the flywheel. Turn the crankshaft clockwise (as seen from the front of the engine) one full turn (360°), and install the bolt again.10. With the timing pin in the notch of the fuel injection pump camshaft and the timing bolt in the flywheel, tighten the bolt which holds the drive gear to the fuel injection pump camshaft to a torque of 175 7 N m (130 5 lb ft).11. Check the timing as follows:a. Remove both the timing pin and timing bolt.b. Turn the crankshaft clockwise (as seen from the front of the engine) two full turns, and install the timing pin and bolt again.c. The timing is correct if both the timing pin and timing bolt can be installed at the same time. The timing procedure must be done again if the timing pin and timing bolt cannot be installed at the same time.d. Remove the timing pin and timing bolt when the timing is correct.12. Install the plug in the flywheel housing. 13. Install the gasket and cover (1) on the fuel injection pump housing. 14. Make sure the O-ring seal is in position on plug (18). Put the plug in position in the timing gear cover, and install bolt (14).15. Connect fuel lines (16) and (17) to the fuel transfer pump.16. Connect fuel lines (13) and (15) to the fuel injection pump.17. Align the marks put on lever (12) with the mark on the governor shaft. Connect the lever to the governor shaft.End By:a. install valve coverb. install belt tightenerc. install fuel injection lines