20922444 Volvo.Penta Cover

1. Disconnect the wires (not shown) from the starter. Fasten a hoist to the starter. Remove three bolts (1) and remove starter (2). Remove the gasket. The weight of the starter is 64 lb. (29 kg).2. Remove plug (3) from the flywheel housing. 3. Install tooling (A) in the flywheel housing. No. 1 piston at top center (TC) on the compression stroke is the starting point for all timing procedures. The engine is seen from the flywheel end when direction of crankshaft rotation is given.4. To find top center compression stroke for No. 1 piston, first turn the flywheel clockwise (opposite the direction of engine rotation) approximately 30 degrees. This procedure is to remove all play from the timing gears. Turn the flywheel counterclockwise until a 3/8"-16 NC bolt (4) can be installed in the flywheel through the hole in the flywheel housing. The No. 1 and No. 6 pistons are now at top center position.
If you go past the bolt hole you must start over with Step 2.
5. Remove breather (5) from the valve cover. 6. To see if the No. 1 piston is on the compression stroke, look at the valves of the No. 1 cylinder. The valves will be closed if No. 1 cylinder is on the compression stroke. You must be able to move both rocker arms (6) up and down with your hand.7. If No. 1 piston is not on the compression stroke, remove the 3/8"-16 NC bolt (4) and turn the flywheel 360° counterclockwise. Install the 3/8" bolt as before. The No. 1 piston is now at top center (TC) on the compression stroke. 8. Remove cover (7) from the front of the timing gear cover. 9. Install timing pin (8) [tool (C)] through the left top hole (as seen from the front of the engine) in the fuel injection pump gear and through the groove (slot) in the sleeve and into the hole in the adapter of the fuel injection pump. If the timing pin can not be installed at this time, install the timing pin after the fuel injection pump is removed. 10. Loosen bolt (9) that holds the fuel injection pump gear to the sleeve approximately 3.2 mm (.125 in.). 11. Install tooling (B) and loosen fuel injection pump gear (11) from the sleeve. Remove tooling (B). Remove bolt (9) and washer (10). 12. Disconnect the fuel return line (not shown) from bypass valve (13).13. Remove fuel injection lines (12) from the engine. Put plugs or caps on all the openings. 14. Remove oil supply line (15) and oil drain line (14). 15. Remove fuel supply lines (16) and (17).16. Put plugs or caps in the openings. 17. Remove bolts (19) that hold the fuel injection pump spacer to bracket (18). 18. Remove three nuts (21) and remove fuel