20793636 Volvo.Penta Connecting rod

start by:a) remove hood1. Remove the panel assembly from the left side of the rear frame.2. Shut off the fuel supply line to the engine. 3. Disconnect linkage (5) from the governor control lever.4. Remove drain hose (7) from the fuel injection pump housing.5. Disconnect fuel lines (1), (2) and (8) from the fuel injection pump.6. Remove fuel injection lines (3) from the engine.
Put protection caps (5F2807) and plugs (2F2990) on the fuel injection lines, pumps and fuel injection nozzles to keep dirt and foreign material out of the fuel system. Also put caps and plugs on all other fuel system openings.
7. Loosen the adjustment nuts and bolts for the alternator to remove the tension on belts (4). Remove belts (4) from the engine.8. Remove cover (6) from over the fuel injection pump drive gear. 9. Remove bolt (9) and the washer and install tooling (B) on the end of bolt (9). Install and tighten the bolt, washer and tooling (B) to hold the sleeve on the end of the fuel injection pump camshaft. 10. Install tooling (A) on the drive gear as shown. Tighten the center bolt of tooling (A) until the drive gear is loose. Remove tooling (A), bolt (9) and the washers. The drive gear will stay in the timing gear cover.
TYPICAL EXAMPLE11. Fasten a hoist to the fuel injection pump housing and governor (10). Remove bracket (11). Remove three nuts (12) and remove the fuel injection pump housing and governor. The weight of the fuel injection pump housing and governor is 50 lb. (23 kg). Check the condition of the O-ring seal in the body assembly of the fuel transfer pump. If the seal has damage, use a new part for replacement.Install Fuel Injection Pump Housing And Governor
1. Put the No. 1 piston at the top center compression position before the fuel injection pump housing and governor are installed on the engine with the following procedure: a) Remove plug (1). Tooling (A) can be used to turn the engine to put the No. 1 piston on top center (TC) compression. If tooling (A) is used, remove the electric starting motor and install tooling (A) in the flywheel housing. If tooling (A) is not used, the engine can be turned with the bolt that holds the pulley for the vibration damper.b) Turn the crankshaft clockwise (as seen from the front of the engine) until a 3/8"-16 NC bolt can be installed in the hole from which plug (1) was removed. The bolt must go through the hole in the flywheel housing and into the threaded hole in the flywheel.
Never turn the crankshaft counterclockwise to install the bolt in the flywheel. If the crankshaft is turned counterclockwise the gear clearance (backlash) can cause the engine to be out of time when the fuel injection pump housing and governor are installed.
c) Disconnect breather tube (2) and the glow plug wire assembly from the valve cover. Remove valve cover (3) from the engine.d) Check to see if both rocker arms 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.e) If both rocker arms can not 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.
TYPICAL EXAMPLE2. Remove timing pin (4) from storage hole (5). Remove the bolt from the cover and install the timing pin in the groove (slot) in the fuel injection pump camshaft.3. Inspect the O-ring seal for the fuel transfer pump. Install a new seal if needed. Put clean engine oil on seal. Put the fuel injection pump housing and governor in position on the engine. Install the nuts that hold it in place.4. Install the washer and bolt that hold the pump drive gear to the camshaft. Tighten the bolt finger tight only.
TYPICAL EXAMPLE5. Put a force of approximately 50 lb.ft. (70 N m) on the drive gear with tool (B). Tighten the bolt to a torque of 110 5 lb.ft. (149 7 N m).6. Check the timing to make sure it is correct: a) Remove the timing pin from the pump camshaft and the bolt from the flywheel.b) Turn the crankshaft clockwise (as seen from the front of the engine) approximately 1/2turn. Install the timing pin again.c) While the crankshaft is turned clockwise (as seen from the front of the engine), push on the timing pin until it slides into the groove (slot) in the pump camshaft.d) Install the bolt in the flywheel. The timing is correct when the bolt is installed in the flywheel and the timing pin is installed in the groove (slot) in the pump camshaft.e) Remove the timing pin and the bolt. Install the plug in the flywheel housing. Install the bolt in the cover on the pump housing.7. If an engine turning tool was used, install the electric starting motor. 8. Install the gasket and cover (11). Install the nuts and washers that hold the cover in place. Tighten the nuts to a torque of 20 5 lb.ft. (25 7 N m).9. Install the valve cover. See VALVE COVER.10. Install the bracket that holds the governor end of the pump housing to the cylinder block.11. Install fuel injection lines (6) and tighten the nuts to a torque of 30 5 lb.ft. (40 7 N m).12. Connect fuel lines (7), (10) and (12) to the fuel injection pump.13. Install drain hose (9).14. Connect linkage (8) to the governor control lever.15. Install vee belts (13). See INSTALL ALTERNATOR for the correct belt tension adjustment.16. Install the panel assembly on the left side of the rear frame.17. Open the fuel supply to the engine.end by:a) install