20856724 Volvo.Penta Heat shield

START BY:a. remove fuel injection pump housing and governorb. remove governorc. remove fuel transfer pump
Be careful not to damage the inlet and outlet ports on the bottom of the pump housing. The pump housing must be put on blocks before disassembly.
1. Remove bolts (1) and (3), cover (4) and housing (2) from the fuel injection pump housing. 2. Remove shaft assembly (5) from housing (2). 3. If necessary, remove gear (6) from the shaft assembly. Bearing (7) will be damaged when removed.4. Remove bearing (7) from the housing. 5. Remove bolts (9), retainer (10) and camshaft gear (8) from the camshaft.
The camshaft is now free to slide out of the fuel injection pump housing. Use care when the pump housing is moved.
6. Make sure tool (D) is in position in the fuel injection pump housing and the racks are in the center (zero) position.7. Remove felt washers (11) from the fuel pumps.8. Use tooling (A) and (B) to remove bushings (12) from the fuel injection pump housing. Put a small amount of downward pressure on tool (B) to make removal of bushings (12) easier. 9. Put identification marks on each fuel pump as to its location in the pump housing for assembly purposes.10. Hold the fuel racks against tool (D) in the center (zero) position and carefully remove each fuel pump with tool (B). 11. Remove the bolt and bracket assembly (13) from the fuel injection pump housing. 12. Put identification marks on fuel racks (14) for assembly purposes. Remove link (15) and fuel racks (14) from the fuel injection pump housing.13. If necessary, remove pin (16) from the fuel injection pump housing. 14. Remove spacers (18) and lifters (17) from the fuel injection pump housing. Put identification marks on each of the spacers and lifters as to their location in the pump housing for assembly purposes. 15. Carefully remove camshaft (19) from the fuel injection pump housing. 16. Remove bypass valve assembly (20) from the fuel injection pump housing. 17. Remove O-ring seals (21) from bypass valve assembly (20).18. Remove pin (22); then remove the piston and the spring from bypass valve assembly (20). 19. Remove bolts (23) and cover (24) from the fuel injection pump housing. When pinion gear (27) is removed, a replacement of drive gear (26) must be made.20. Remove idler gear (25) from the fuel injection pump housing.21. Use a soft hammer and remove pinion gear (27) from the fuel injection pump housing.22. Remove drive gear (26) from the fuel injection pump housing. 23. Use tool (C) and remove dowels (28) and (30) and shaft (29) from the fuel injection pump housing.24. Remove lower and upper bearings (31) from the fuel injection pump housing.25. If necessary, remove plug (32) from the fuel injection pump housing. 26. Remove the fuel rack bearings from locations (33) in the fuel injection pump housing.27. Use tool group (E) and remove the camshaft bearings from the fuel injection pump housing.Assemble Fuel Injection Pump Housing
1. Clean and inspect all parts of the fuel injection pump housing for wear or damage and make a replacement if necessary. 2. Put fixture assembly (1) [part of tooling (A)] on the pump housing with the dowels in fixture (1) engaged in the right rack bore. Install bolt (4).3. Put a new bearing (2) in position between fixture (1) and the rack bore with the tab of the bearing up. Install the bearing with driver (3) [part of tooling (A)] until the shoulder of the driver makes contact with the fixture. 4. Turn the fixture and make an alignment of the dowels on the fixture with the left rack bore. Install the right rack bearing in pump housing (5) according to the instructions in Step 3. After assembly check to make sure the fuel rack bearings are installed 19.1 0.5 mm (.75 .02 in.) below the outside surface and the center of the bearing tabs are within 0.05 mm (.002 in.) of a line through the center of the bearings and parallel to the vertical center line of the injection pump housing. Install all camshaft bearings with the bearing joint in area "Y". This will put the oil hole in area "X".5. Install camshaft front bearing (7) with tooling (B). Install the bearing until it is 1.0 0.5 mm (.04 .02 in.) from front surface (6) of the fuel injection pump housing. 6. Install center bearing (9) with tooling (B) until the rear edge of the bearing is 127.00 0.51 mm (5.000 .020 in.) from rear surface (8) of the pump housing.7. Install rear bearing (10) with tooling (B) until it is 4.83 0.51 mm (.190 .020 in.) from rear surface (8). After assembly, the inside diameter of all the bearing must be 53.988 0.038 mm (2.1255 .0015 in.). 8. Use tool group (C) and install the two bearings into the fuel injection pump housing as follows:a. Install the lower bearing with the notched side up and until it is 28.4 0.5 mm (1.12 .02 in.) below surface (V). Make sure the center of the notch in the bearing is 10 5° from the horizontal center line of the bearing bore as shown. After assembly the inside bearing diameter must be 19.093 0.038 mm (.7517 .0015 in.).b. Install the upper bearing with the notched side up and even with or not more than 0.15 mm (.006 in.) below surface (V). Make sure the center of the notch in the bearing is 10 5° from the horizontal center line of the bearing bore as with or not more than shown. After assembly, the inside bearing diameter must be 19.093 0.038 mm (.7517 .0015 in.).9. Install shaft (11) in the fuel injection pump housing until it extends 16.8 0.5 mm (.66 .02 in.) above surface (V). 10. Put