948812 Volvo.Penta Cap plug

WRENCH INSTALLED
1. 8S2243 Wrench. 2. Protective cap. 3. Retaining bushing.c. Install extractor (4).d. Remove retaining bushing (3) and wrench (1).e. Remove the seal and lift fuel injection pump (5) out of the housing. Keep components together and identified as to location.4. Remove rack (7) and rack bumper spring (6).
REMOVING PUMP
4. 8S2244 Extractor. 5. Fuel injection pump.
REMOVING RACK
6. Rack bumper spring. 7. Rack.5. Use magnet (8) to remove lifters (9). Identify lifters (9) and keep them with their respective fuel injection pumps.
REMOVING LIFTERS
8. 8S2293 Magnet. 9. Lifter.6. Remove the camshaft gear assembly retaining bolt (11) and lock. Remove plate assembly (10).
REMOVING PLATE ASSEMBLY
10. Plate assembly. 11. Bolt.7. Remove camshaft gear assembly (12) from camshaft (13).
REMOVING GEAR ASSEMBLY
12. Gear assembly. 13. Camshaft.
REMOVING BOLTS
14. Lock. 15. Bolts.8. Remove bolts (15) and lock (14).9. Remove camshaft retaining plate (16).
REMOVING RETAINING PLATE
16. Retaining plate.10. Remove camshaft (13).
REMOVING CAMSHAFT
13. Camshaft.11. Use camshaft bearing removal and installation group (17) to remove the camshaft bearings from the fuel injection pump housing.
REMOVING BEARINGS
17. 8S2241 Camshaft Bearing Removal and Installation Group.Assemble Fuel Injection Pump Housing
1. Use camshaft bearing removal and installation group (17) to install the camshaft bearings in the fuel injection pump housing. The camshaft bearings must be installed with the oil holes in the bearings in line with the oil hole in the housing. The front and rear bearings must be line bored after installation. To align oil holes and line bore the bearings, See Special Instruction (GMG00672).
INSTALLING BEARINGS
17. 8S2241 Camshaft Bearing Removal and Installation Group.2. Put clean engine oil (SAE 30) on the camshaft and install camshaft (13) in the fuel injection pump housing.
INSTALLING CAMSHAFT
13. Camshaft.3. Install the camshaft retaining plate (16).4. Install lock (14) and bolts (15).
INSTALLING RETAINING PLATE
16. Retaining plate.
INSTALLING BOLTS
14. Lock. 15. Bolts.5. Install camshaft gear assembly (12) on camshaft (13).
INSTALLING GEAR ASSEMBLY
12. Gear assembly. 13. Camshaft.6. Install plate assembly (10), retaining bolt (11), and lock.
INSTALLING PLATE ASSEMBLY
10. Plate assembly. 11. Bolt. Be sure to put the spacer on bolt (11).7. Use magnet (8) to install lifters (9). The lifters (9) must be installed in the same location from which they were removed.
INSTALLING LIFTERS
8. 8S2293 Magnet. 9. Lifters.8. Lubricate the rack with clean fuel oil. Install rack (7) with timing pin slot in rack toward front of the housing. Install rack bumper spring (6) so the large diameter of the bumper spring will be against the housing. If new lifters and pumps are to be installed it will be necessary to check and/or adjust the fuel pump timing dimension. See FUEL PUMP TIMING DIMENSION SETTING-OFF ENGINE in TESTING AND ADJUSTING section of the Service Manual.
INSTALLING RACK
6. Rack bumper spring. 7. Rack.9. Remove bolts (19) and rack cover (18).
RACK COVER
18. Rack cover. 19. Bolts.
TIMING PIN INSTALLED
20. Slot in rack. 21. 8S2291 or FT887 Timing Pin.10. The rack must be centered to install the fuel injection pumps. To center the rack, pull the rack toward the governor end of the housing until centering slot (20) in the rack is under the centering pin hole. Insert a timing pin (21) in the centering hole and push the rack toward the front of the housing until slot (20) in the rack is against the timing pin. The rack is now centered.11. With the rack centered, install the fuel injection pumps as follows: a. Rotate the camshaft until camshaft lobe for pump to be installed is down or at lowest point.b. Install extractor (4) on the pump (5).c. Align notches in bonnet and barrel with pump gear segment center tooth.
ALIGNING NOTCHES IN BONNET AND BARREL WITH PUMP GEAR SEGMENT CENTER TOOTHd. Position the pump (5) so the notches in bonnet and barrel align with the dowels in the housing and the pump gear segment center tooth aligns with the center notch in the rack. Install each pump (5) in their respective position in the housing.
INSTALLING PUMP
4. 8S2244 Extractor. 5. Fuel injection pump.e. Install the seal and retaining bushing. Apply a downward force (by hand) to the extractor (4) and tighten the retaining bushing (3) by hand (finger tight only) until the top of the retaining bushing threads are flush with the top of housing. If the retaining bushing can not be installed this far by hand, remove it. Remove pump, realign components and install again.
TIGHTENING PUMP
3. Retaining bushing. 4. 8S2244 Extractor.
Do not force the top of the bushing threads flush with the top of the pump housing by using a wrench. If pump is installed correctly, retaining bushing can be finger tightened this far.
f. After each pump is installed, check total rack travel in the following manner: Install bracket assembly (23) on the housing, install contact point (24) on dial indicator (22) and install the indicator in bracket assembly (23). Zero the dial indicator. Do this by moving the indicator back and forth within the mounting bracket until the revolution counter lies between the red zero and black zero. Tighten the dial indicator retaining bolt. Now place the zero on the large dial under the indicator large hand by rotating the dial face. Remove the timing pin and check the total rack travel. Total rack travel should be approximately .624 in. (15.85 mm). A pump installed one tooth off will reduce rack travel approximately .100 in. (2.54 mm). If total rack travel can not be obtained, remove the pump, realign components, and again install pump.
CHECKING RACK TRAVEL
22. 8S2283 Dial Indicator. 23. 9S225 Bracket Assembly. 24. 3S3269 Contact Point.g. After each pump is installed correctly remove the extractor. Install the 8S2243 Wrench and tighten the retaining bushing to 100 10 lb. ft. (13.8 1.4 mkg). Remove the wrench and install the protective cap.12. After all the pumps are in the housing, install the governor to the fuel injection pump housing.13. Install fuel injection pump housing and governor on the engine as a unit.14. Adjust governor and set the rack. See the topics GOVERNOR ADJUSTMENTS and FUEL RACK SETTING in TESTING AND ADJUSTING section of the Service Manual.