3803665 Volvo.Penta Cylinder head

start by:a) separation of governor from fuel injection pump housing 1. Remove the protection caps and felt washers (1) from pumps.2. Use wrench (A) to remove bushings (2) that hold the fuel injection pumps into the housing. Remove seals (3).3. Use extractor (B) to remove the pumps from the pump housing. Put identification on the injection pumps as to their location in the pump housing.4. Remove bonnet (4), ring (5), spring (6) and check valve (7) from barrel (8).5. Remove plunger assembly (11), washer (10) and spring (9) from the barrel.
Be careful not to cause damage to plunger assemblies. Keep the same cylinder pump and plunger together, the plunger from one pump can not be installed in another group.
6. Remove rack (12) from the housing. 7. Remove spacers (13) and lifters (14) from the housing. Keep the spacers and lifters together with identification as to their location in the pump housing. 8. Remove two bolts (16), lock and two sleeves from the gear assembly.9. Remove gear assembly (15) from the camshaft. 10. Remove two bolts, plate (17) and the spacer that hold the camshaft in position in the pump housing. 11. Remove the camshaft from the pump housing. 12. Use tool group (C) to remove the camshaft bearings from the pump housing.13. Remove the bearings for the fuel rack from the pump housing.Assemble Fuel Injection Pump Housing
1. Use tooling (C) to install the camshaft bearings in the fuel injection pump housing. Install the camshaft bearing joints 15° from the vertical centerline of the bores. Install the front and rear camshaft bearings even with the fuel injection pump housing. Install the center camshaft bearing a distance of 4.81 .02 in. (122.2 0.5 mm) from the rear face of the fuel injection pump housing. 2. Use tooling (F) to install the bearing with a tab for the groove in the rack.3. Use tooling (E) to install the rear bearing for the rack. Install the bearing to a depth of .282 .005 in. (7.16 0.13 mm). The small holes in the rear bearing must be installed parallel to the vertical centerline of the pump. 4. Put clean engine oil on the camshaft. Install the camshaft in the pump housing. 5. Install the spacer, plate (1) and two bolts that hold the camshaft in place in the pump housing. 6. Put gear assembly (2) in position on the end of the camshaft. Be sure rod (3) is in the groove of the camshaft. 7. Install sleeves (4), lock and two bolts on the gear assembly. 8. Install spacers (5) with their respective lifters (6) in the pump housing. If new lifters and/or pumps are to be installed, make adjustment of the fuel pump timing dimension. See SETTING THE INJECTION PUMP TIMING DIMENSION: OFF ENGINE TESTING AND ADJUSTING. 9. Install rack (7) in the pump housing.10. Assemble the fuel injection pumps as follows: a) Put clean fuel on all parts.b) Install the spring, washers and plunger in the barrel.c) Install the spring, check valve, bonnet and ring on the barrel.
The plunger from one pump can not be installed in another pump. Do not install the pumps until rack (7) is in center position (centered).
11. Use pointer group (D) to put rack (7) in center position. Push the rack into pointer (D) to get the center position. The rack will be extended .156 in. (3.962 mm) from the end of the pump housing (opposite the governor) when the rack is in the center position.12. Install the fuel injection pumps with extractor (B). Turn the camshaft until the lobe of the camshaft is down on the pump to be installed. Look down the pump and make grooves in the bonnet and barrel in alignment with the groove (slot) in the pump gear. The groove (slot) of the gear must be in alignment with the center of these grooves. Put the pump so the grooves are in alignment with the guide pins in the housing bores. Install the pump in its respective bore in the housing. 13. Install seal (8) and bushing (9). Put pressure by hand on extractor (B). Tighten the bushing by hand (finger tight only) until the bushing is even with the top of housing. If the bushing can not be installed by hand, remove the bushing and pump. Make grooves in alignment and install again.
Do not put force on bushings with a wrench to make them even with pump housing. Pump is not installed correctly if a force has to be used to install bushing.
14. Check the rack movement (travel) after each pump is installed. Total rack movement (travel) must be .800 in. (20.32 mm). See INSTALLATION OF INJECTION PUMPS in TESTING AND ADJUSTING.15. Tighten the bushing with wrench (A) to 150 10 lb.ft. (205 14 N m). Remove wrench (A) and install felt seals and protection caps.end by:a) connection of governor to fuel injection pump housing