11032003 Volvo.Penta Flywheel housing

1. Remove plug (1). Install tool (A) in the hole with the square end "X" down. Move the governor control the "ON" position until the rack stops against tool (A). The racks are now in center (zero) position. 2. Disconnect lines (2) from the fuel injection pumps. Put caps on all fuel openings.3. Use tool (B) to loosen the bushings. 4. Remove fuel injection pump with tool (C). Remove tool (C) and bushing (3) from the fuel injection pump. Remove the washer from bushing (3) and remove seal from under bushing.
When injection pumps, spacers and lifters are removed from the injection pump housing, keep the parts of each pump together so they can be installed back in their original location.
5. Disassemble the fuel injection pump. Remove ring (4). Make a separation of the bonnet from the plunger and barrel assembly (5).
Be careful when the fuel injection pumps are disassembled. Do not damage the surfaces 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.
6. Remove the gear segment, washer and spring from the barrel.7. Remove the ring, spring, collar and valve from the barrel. 8. Remove spacer (6) from the fuel injection pump housing.Install Fuel Injection Pumps
Make sure the fuel racks are in the center (zero) position before the fuel injection pumps are installed. 1. Put plunger (5), washer (6) and spring (4) in position on barrel (9). Put check valve assembly (3) and spring (8) in position in bonnet (7). Connect bonnet (7) and barrel (9) together with ring (2). Keep seal (1) with bonnet for use at installation. 2. Put spacer (12) into position in the pump housing bore. Make sure the correct spacer is with each pump.3. Put the spacer in gear segment (10) in alignment with the groove in barrel (9). The lobe on the cam must be at its lowest position for easy installation of the injection pumps. 4. Put the injection pump straight down into the housing bore so the space in gear segment (10) is in alignment with pin (11) and the groove in barrel (9) is in alignment with dowel (13). Use tool (C) to install the pump. 5. Install seal (1) and bushing (14) in the pump housing bore. If the pump is in the correct position, bushing (14) will turn into the threads of the pump housing with the fingers until it is even with the housing. Tighten bushing (14) to a torque of 205 14 N m (150 10 lb.ft.) with tool (B).6. Install the washer on bushing (14).7. Connect the fuel lines to the injection pumps and tighten fuel line nuts to a torque of 40 7 N m (30 5 lb.ft.).8. Check the correct installation of the injection pumps with the engine stopped. See INSTALLATION OF INJECTION PUMP in TESTING AND ADJUSTING.
If one or more of the injection pumps have been installed wrong, damage to the engine is possible if cautions are not taken when the engine is first started. Make preparation to close off the air intake to stop the engine if necessary.
9. Remove the timing pin [tool (A)] and install the plug in the injection pump housing.