831868 Volvo.Penta Cylinder liner kit

1. Remove nuts (1), cover (2), and the gasket. 2. Remove four bolts (3). Remove governor and fuel pump drive (4). Remove the O-ring seals from the governor and fuel pump drive. 3. Remove gear (6) from fuel injection pump camshaft (5).Install Governor & Fuel Pump Drive
1. Remove the plug from the timing pin hole in the fuel injection pump housing, and install Tool (A) in the timing pin hole.2. Install two 7/16-20 NF × 102 mm (4 in) long bolts in fuel injection pump camshaft (1). Slowly rotate the fuel injection pump until Tool (A) goes into the groove in the fuel injection pump camshaft. Remove the bolts from the camshaft. 3. Put No. 1 piston at the top center compression position (TC) with the following procedure: a. Remove plug (3), timing bolt (4) and cover (2) from the flywheel housing. b. Install Tool (B) in the flywheel housing. Use Tool (B) to slowly rotate the engine in the direction of normal rotation (counterclockwise as seen from the flywheel end of the engine) until timing bolt (4) can be installed in the flywheel housing and into the hole in the flywheel. c. Remove the valve cover from the valve cover base. Check to see if both rocker arms (5) for the No. 1 cylinder can be moved backward and forward. The No. 1 piston is at the top center compression position (TC) when the timing bolt is installed in the flywheel and both rocker arms for the No. 1 cylinder can be moved backward and forward. If both rocker arms cannot be moved, the No. 1 piston is not at the top center compression position (TC) Remove the timing bolt from the flywheel and rotate the engine in the direction of normal rotation (counterclockwise as seen from the flywheel end of the engine) on full turn 360 degrees, and install the timing bolt again.4. Remove the timing bolt, and use Tool (B) to rotate the engine in the opposite direction of normal rotation (clockwise as seen from the flywheel end of the engine) a minimum of 30 degrees. 5. Put gear (6) in position on the fuel injection pump camshaft. 6. Put two O-ring seals (8) in position on governor and fuel pump drive (7).7. Put the governor and fuel pump drive in position on the fuel injection pump camshaft, and install the four bolts. Tighten the bolts to a torque of 3 N m (27 lb in).8. Use Tool (B) and slowly rotate the engine in the direction of normal rotation until the timing bolt can be installed in the flywheel.9. Tighten the bolts that hold the governor and fuel pump drive to the fuel injection pump camshaft to a torque of 55 7 N m (41 5 lb ft).10. Remove Tool (A) from the fuel injection pump housing, and remove the timing bolt from the flywheel.11. Check the timing as follows: a. Rotate the engine in the direction of normal rotation (counterclockwise as seen from the flywheel end of the engine) two full turns, and install Tool (A) and the timing pin again.b. The timing is correct if Tool (A) and the timing bolt can be installed at the same time. The timing procedure must be done again if the timing bolt and Tool (A) can not be installed at the same time.c. Remove Tool (A), and install the plug in the fuel injection pump housing. Remove the timing bolt and Tool (B), and install the plug and cover on the flywheel housing. 12. Put the gasket and cover (9) in position on the timing gear cover, and install the nuts. Disassemble Governor & Fuel Pump Drive
Start By:a. remove governor and fuel pump drive 1. Remove seals (1) from the body.
Spring force is present behind carrier (3). Put downward pressure on carrier (3) when bolts (2) are removed.
2. Remove bolts (2) from ring (4). 3. Remove ring (4) and the carrier from ring (5). 4. Remove springs (6) and ring (5) from retainer assembly (7). 5. Remove the locknut and setscrew (8). Remove the locknut and screw (9) from the retainer assembly. 6. Remove ring (4) from carrier (3).7. Remove seal (10) from carrier (3). 8. Remove bolts (11) and carrier (12) from carrier (3). 9. Remove lockring (13) and body (14) from the carrier. 10. Install two 3/8 -16 NC Bolts into the body as shown. Clamp the bolt heads in a vise, and remove plug (15) from body (14). 11. Remove ring (16) and race (17) from spool (18), and remove spool (18) from the carrier. 12. Remove dowels (19) and flyweights (20) from the carrier.Assemble Governor & Fuel Pump Drive
1. Put flyweight (1) in position on carrier (2), and install dowels (3) that hold the flyweights in position. 2. Put spool (4) in position on the carrier, and install race (5) and ring (6) on the end of spool (4). 3. Install two 3/8 -16 NC Bolts into body (7) as shown. Clamp the bolt heads in a vice, and install plug (8). Tighten plug (8) to a torque of 70 15 N m (50 11 lb ft). 4. Install body (7) into carrier (8), and install lockring (9). 5. Put carrier (2) in position on carrier (8), and install the bolts that hold it. 6. Install seal (9) on carrier (8). Put clean engine oil on the seal, and install ring (10) on carrier (8). 7. Install setscrew (11) and the locknut. Install the screw and locknut (12) into the retainer assembly. Tighten locknut (12) to a torque of 70 15 N m (50 10 lb ft). 8. Place ring (13) and two springs (14) in position on retainer (15).9. Place ring (16) and the carrier in position on ring (13). Make sure that the small spring fits over the end of the spool in the carrier assembly. 10. Use two 3/8 -16 NC × 89 mm (3.5 in) long bolts, washers and nuts to