21460971 Volvo.Penta Crankshaft

1. Disconnect four fuel lines (1). Cap and plug all openings immediately.2. Disconnect connector (2). 3. Disconnect two fuel lines (4). Cap and plug all openings immediately.4. Remove wire (5).5. Disconnect two connectors (3). 6. Disconnect hose (6). Cap and plug all openings immediately.7. Disconnect four connectors (7). 8. Remove two bolts (8).9. Remove eleven bolts (11).10. Remove bracket (9) and cover (10) together. 11. Remove four bolts (14) and spacer (12). At assembly, torque bolts (14) to 230 15 N m (170 11 lb ft).12. Remove drive gear assembly (13). 13. Remove three bolts (15).14. Remove bolt (16).15. Remove bracket (17). 16. Remove tube (18). Cap and plug all openings immediately. 17. Remove three bolts (21).18. Remove bolt (20) and bracket (19). 19. Attach a hoist to pump (22) as shown. Remove the pump. The weight of the pump is 91 kg (201 lb). Reverse the order of Steps 1 thru 19 for installation.20. Time the fuel injection pump. See the Systems Operation, Testing & Adjusting Manual for this procedure.End By:a. install fuel injection linesDisassemble Governor & Fuel Injection Pump Housing
Start By:a. remove fuel transfer pumpb. remove governor and fuel injection pump housing FLUID SPILLAGE CONTAINMENT Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates. 1. Remove five bolts and washers (1), cover (2) and the gasket. 2. Disconnect receptacle (3).3. Put identification marks on wires (4) for assembly. Use Tool (B) to disconnect wires (4). 4. Remove three bolts and washers (6), bracket assembly (5), electronic control (7) and the gasket. 5. Remove five bolts and washers (8), housing assembly (9) and the gasket from fuel injection pump housing (10). 6. Remove two bolts, one clip and two clamps (12).7. Remove solenoid (11) and the seal from housing assembly (9). 8. Remove shutoff solenoid (13) with Tool (E) and the seal. 9. Remove receptacle (3) from clip assembly (14).10. Remove two bolts and washers (15) and clip assembly (14). 11. Remove lever group (16) from housing assembly (9). 12. If necessary, remove spring (17) from lever group (16). 13. Loosen jam nut (18).14. Remove control group (19) from housing assembly (9). If necessary, remove the O-ring seal. 15. Remove spring (20) from control group (19). 16. Remove retaining ring (21) and shaft (22). 17. If necessary, remove retaining ring (23) and lip seal (24). 18. If necessary, remove spring (25). 19. Remove four bolts (26), rotary servo group (27) and the gasket from fuel injection pump housing (10). 20. Remove two bolts (28), cover (29) and the gasket. 21. Remove spring (30) and valve (31) from rotary servo body.22. Remove bolt (32) and body assembly (33). 23. Remove three O-rings (34) and shaft assembly (35). 24. Separate shaft (39) from star gears (36) and (37).25. Remove key (38) if necessary. 26. Remove sensor (42).27. Remove bolts (40) and drive housing (41). 28. Remove tube assembly (43).29. Remove bolt and washer (44). Remove rack control bar (45). 30. Remove two bolts (46) and servo piston assembly (47). 31. Remove retaining ring (48), spring seat (49), link spring (50), rack control sleeve (51) and ring (52) from servo piston assembly (47). 32. Remove sleeve (55), piston (54) and valve (53) from servo piston assembly (47). Remove the O-ring seal from sleeve (55). 33. Remove two bolts (56) and pump drive gear (57). 34. Remove the bolt and plug (61) and rack link (60).35. Remove two bolts (59), support assembly (58) and the pin. 36. Remove the washers. Use Tool (A) to remove twelve bushings (62) and the seals. 37. Install Tool (D) in the pump housing with the square end down (end with taper will be up). Hold the racks against Tool (D) and remove each of fuel injection pumps (63) with Tool (B). For more detail, see the topic, "Remove Fuel Injection Pumps" in this module. Mark pumps (63) so they may be returned to their original location at assembly. 38. Mark for identification at assembly right and left hand rack regulators (64). Remove both rack regulators. 39. Remove six bolts (65), two bolts (66), the plate assembly and the gasket from fuel injection pump housing (10). 40. Remove bypass valve (67) and the O-ring seal. If necessary, press out adapter (68). 41. Remove bypass valve assembly (69) from valve body (73).42. Remove O-ring seal (70) from bypass valve assembly (69).43. Remove spring (71) and bypass valve (72) from housing (73). 44. Use a seal pick to remove valve lifters (74) and the spacers. Put identification on each of the spacers and lifters as to their location in the pump housing. 45. Remove two bolts (75) and the locking tabs.46. Remove camshaft lock (76).