3803027 Volvo.Penta Cylinder head

Start By:a. remove mufflerb. remove fuel injection lines See the topic "Finding Top Center Compression Position For No. 1 Piston And Camshaft Timing For The Fuel Injection Pump" in the Engine Systems Operation Testing And Adjusting module, Form No. SENR4642.1. Put the fuel injection pump in correct timing with the engine as follows: a. Remove plug (1) from the governor plate. Turn the engine with tool (A) to put the No. 1 piston at top center compression stroke. b. Install tool (B) in the opening in the governor plate to engage with the timing groove in the fuel injection pump camshaft.2. Disconnect fuel lines (2) from the fuel transfer pump.3. Remove fuel line support bracket (3). 4. Disconnect fuel lines (4) from the governor plate. 5. Remove cotter pin (7) and pin (5) that hold governor control linkage (6) to governor housing (8). 6. Disconnect air line (10) from fuel ratio control (9).7. Disconnect the fuel shutoff solenoid wires at connector (11).
Do not let retainer (12) drop in the front housing.
8. Remove the four bolts and retainer (12) which hold the automatic timing advance to the fuel pump camshaft. 9. Remove bolts (14), the washers, spacers and bracket (13) from each side of the fuel injection pump housing. 10. Fasten tool (C) to the governor plate as shown. Fasten a hoist to tool (C).11. Carefully pull the fuel injection pump housing out of the timing gear housing.12. Remove the fuel injection pump housing and governor from the engine. The weight of the unit is 50 kg (110 lb). 13. Check the condition of the two O-ring seals on the bottom and seal (15) on the front of the fuel injection pump housing. If the seals are worn or damaged, use new parts for replacement.Install Fuel Injection Pump Housing & Governor
Be sure there is no paint, dirt and foreign material on the machined surface of the fuel injection pump housing and the machined surface of the cylinder block. The surfaces must be clean before the fuel injection pump housing and governor are installed.
1. Put 5P0960 Multipurpose Grease on the two O-ring seals that fit into the bottom of the fuel injection pump housing. The grease will hold the seals in place. Install the two O-ring seals in the bottom of the fuel injection pump housing. Install O-ring seal (1) on the front of the fuel injection pump housing. Put clean engine oil on the seal.2. Turn the fuel injection pump camshaft until tool (A) can be installed in the groove in the fuel injection pump camshaft.3. Install tool (B) on the governor plate as shown.4. Fasten a hoist to tool (B) in the fuel injection pump housing and governor. Put the unit in position on the engine. Be sure the fuel injection pump camshaft is in the automatic timing advance unit and the bolt holes in the fuel injection pump housing are in alignment with the holes in the engine. 5. Install the spacers, washers, bolts (3) and brackets (2) on each side of the fuel injection pump housing. 6. Connect fuel shutoff solenoid wires at connector (11).7. Connect governor control linkage (6) to the lever with pin (5) and cotter pin (7).8. Connect air line (10) to fuel ratio control (9). 9. Connect fuel lines (9) to the governor plate. 10. Connect fuel lines (11) to the fuel transfer pump.11. Install the retainer and bolt that hold the automatic timing advance unit on the fuel injection pump camshaft. Tighten the bolt to a torque of 27 N m (20 lb ft) with tool (A) (timing pin) in the fuel pump camshaft.12. Remove the timing pin, and tighten the bolt to a torque of 135 7 N m (100 5 lb ft). 13. Install the gasket and cover (12) for the automatic timing advance.End By:a. install fuel injection linesb. install muffler