477024 Volvo.Penta Expansion plug

1. Install tools (A) and (B) on the fuel injection pump. Use tool (A) to loosen the bushing. Remove tools (A) and (B). 2. Remove the bushing and O-ring seal (1) from the fuel injection pump and pump housing. Do not loosen screws (3) when the fuel injection pump is removed or installed. If the levers are moved, the fuel pump calibration will be changed.3. Install tool (B) on fuel injection pump (2). Remove fuel injection pump (2) from the fuel injection pump housing. The sleeve on the plunger will slide off on the lever as the fuel injection pump is removed. Keep the sleeve and plunger with their respective barrel for installation. Do not mix sleeve, plunger and barrel with other sleeves, plungers and barrels.4. Do Steps 1 through 3 again to remove the other fuel injection pumps.Install Fuel Injection Pumps
Make sure the sleeve is installed with the thin edge up.
1. Install tool (A) on fuel injection pump (1). Put pump (1) in position in the bore of the fuel injection pump housing. Make sure the groove in sleeve (2) is engaged with lever (3).
If lever (3) has moved on the shaft, fuel pump calibration must be made. See Testing And Adjusting.
2. Install O-ring seal (5) and bushing (4) over the fuel injection pump and in the fuel injection pump housing. 3. Use tool (B) to tighten bushing (4) to a torque of 80 7 N m (60 5 lb.ft.).4. Do Steps 1 through 3 for the other fuel injection pumps.End By:a. install fuel injection linesb. install shutoff housing, check valve and bypass valveDisassemble And Assemble Fuel Injection Pumps
Start By:a. remove fuel injection pumps
Be careful when the fuel injection pumps are disassembled. Do not damage the surface of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. The check assemblies are made as a set. Do not mix the parts of the different check assemblies. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
1. Remove ring (2), and separate bonnet (1) and barrel (3).2. Remove spring (7) and check assembly (8) from the bonnet.3. Remove washer (4), plunger (5) and sleeve (6) as a unit from the barrel. Remove washer (4) and sleeve (6) from plunger (5). Remove spring (9) from the barrel.
Install the sleeve on the plunger with the thin edge up. Make sure the sleeve and plunger are installed in their original barrel and the large hole in the plunger is up (toward the barrel).
Put clean fuel oil on all parts before assembly.4. Install spring (9) on barrel (3). Install sleeve (6) and washer (4) on plunger (5). Install sleeve (6), washer (4) and plunger (5) as a unit in the barrel.5. Install spring (7) and check assembly (8) in bonnet (1).
Do not slide bonnet (1) across the face of barrel (3) when ring (2) is installed. The check assembly in the bonnet can put scratches in the face of barrel (3).
6. Put bonnet (1) in position on barrel (3), and install ring (2) to hold the bonnet and barrel together.End By:a. install fuel injection pumps