840638 Volvo.Penta Charge distributor

1. Disconnect tachometer drive cable (1). Disconnect fuel lines (2) and (3) from fuel transfer pump (4). 2. Remove two bolts (5) from the fuel transfer pump. Remove fuel transfer pump (4).Install Fuel Transfer Pump
1. Check seals and gaskets for damage. If damaged, use new parts for replacement. 2. Put the gasket and fuel transfer pump (1) in position on the rear plate.3. Turn the fuel transfer pump to engage the gears.4. Install the two bolts that hold the fuel transfer pump. 5. Connect fuel lines (2) and (3). Connect tachometer drive cable (4). Turn the fuel supply valve to the open position.Disassemble Fuel Transfer Pump
start by:a) remove fuel transfer pump 1. Remove tachometer drive (3) from transfer pump cover (4).2. Remove bolts (1). Make a separation between cover (4) and pump body (2). 3. Remove lip type seal (6) from the cover. Remove plug (5), seal, spring and plunger (bypass valve) from the cover. 4. Remove nut (10) from shaft (7). Remove gear (9) and key (11).5. Remove shaft (7) and gear (8) as a unit. Remove gear (8) from drive shaft (7) with a press.6. Remove idler gear (12). 7. Remove bushing (14), two lip type seals and the bottom bearing from pump body (2).8. Remove check valve (13).Assemble Fuel Transfer Pump
1. Install bushing (4) in body (3) with tooling (B). The bushing must not be extended above the (gear) surface of the body.2. Install the check valve in the body with tooling (A).3. Install lip type seal (5) with tooling (C). Install the seal until it is .97 .02 in. (24.6 0.5 mm) from the bottom surface of body (3) and with the lip toward bushing (4) as shown.4. Install lip type seal (6) with tooling (D). Install the seal until it is .56 .02 in. (14.2 0.5 mm) from the bottom surface of body (3) and with the lip away from seal (5) as shown.5. Install bearing (7) in body (3) with tooling (E). The bearing must be even with the surface of the pump body. 6. Heat gear (8) to a maximum temperature of 600°F (316°C). Install gear (8) on shaft (11) until dimension X is 1.957 .010 in. (49.71 0.25 mm).7. Install the drive shaft and gear in body (3). Install key, gear (10) and nut (9). Tighten the nut to a torque of 22 5 lb.ft. (28 7 N m).8. Install idler gear (12) in body (3).9. Install lip type seal (2) with tooling (C). Install the seal until it is .15 .02 in. (3.8 0.5 mm) from the top surface of cover (1) with the lip toward the inside as shown. 10. Install plunger (14) (bypass valve), spring (15), seal and plug (13) in pump cover (1). Tighten plug (13) to a torque of 27 3 lb.ft. (38 4 N m).11. Put 7M7260 Liquid Gasket Material on the surface of cover (1). Install cover (1) on pump body (3).
Do not let the liquid gasket enter the pump.
The drive shaft must turn freely after the bolts that hold the transfer pump together are tightened.12. Install the service meter and/or tachometer drive on cover (1).end by: a) install fuel transfer pump