940100 Volvo.Penta Hexagon screw

start by: a) separation of governor from fuel injection pump housing1. Remove the fuel injection pumps as follows: a) Remove the protection cap and washer (1). b) Install tool (A) and remove bushing (2) from housing.c) Remove the seal (3). d) Install tool (B).e) Lift the fuel injection pump out of the housing.f) Remove the spacer (4). Keep the spacers (4) and pumps together, and put a mark on them as to their location in the fuel injection pump housing.2. Disassemble the fuel injection pump as follows: a) Remove the bonnet (5), ring (6), spring (7), and check valve (8) from the barrel (9).b) Remove the plunger (10), washer (11), and spring (12) from the barrel (9).
During disassembly and assembly of fuel injection pumps, do not cause damage to plunger surfaces. The barrel and plunger are exactly fitted, and the parts can not be changed with other barrels or plungers.
3. Remove the rack (13).4. Remove the lifters (14). Put identification on the lifters and keep them together with their respective pump and spacers. 5. Remove the camshaft plate (15), bolt and lock. 6. Remove the spring (16) and the gear (17) from the camshaft. 7. Remove the camshaft (19). 8. Remove the camshaft bearings from the fuel injection pump housing with tool (C).9. Remove the two bearings (18) from the fuel injection pump housing.Assemble Fuel Injection Pump Housing (Compact Fuel System)
1. Install the camshaft bearings in the fuel injection pump housing with tool (C). Install the bearing in governor end of housing so the lubrication hole in the bearing is in alignment with lubrication hole in housing. Install the camshaft bearings even with outside ends of fuel injection pump housing. 2. Install the two rack bearings in the fuel injection pump housing with tooling (D). Install the bearing in governor end of housing so it will be .195 .005 in. (4.953 0.127 mm) lower than face of housing. Install the rack bearing in accessory drive end of housing so it will be even with face of fuel injection pump housing. 3. Put clean SAE 30 engine oil on camshaft. Install the camshaft in fuel injection pump housing. 4. Put the governor drive gear (1) and spring (2) in position on the camshaft. Install the camshaft plate (3), bolt, and lock. 5. Install the lifters (4) in their positions in housing. Put clean SAE 30 engine oil on the rack. Install the rack (5) in fuel injection pump housing with the opening in rack near the governor end of housing.6. Install the spacers in their respective positions in housing. When installing new lifters and pumps, it is necessary to make adjustment of the fuel pump timing. See FUEL INJECTION PUMP TIMING DIMENSIONS SETTING, OFF ENGINE in TESTING AND ADJUSTING.7. Assemble the fuel injection pumps as follows: a) Put clean fuel oil on all parts.b) Install the spring, washer, and plunger in the barrel.c) Install the spring, check valve, bonnet, and ring on the barrel.
Do not install fuel injection pumps until the rack has been put in the center position.
8. Put the rack in the center position with tooling (E) as follows: a) Install location fixture (6) on the fuel injection pump housing.b) Install the gauge (7). Move the gauge (7) to zero. Push the rack (5) against the gauge. c) Install the clamp (8) on pump housing as illustrated. This will keep the rack in the center while installing the fuel injection pumps.9. With the rack in the center, install the fuel injection pumps as follows: a) Turn the camshaft until lobe of camshaft is down for pump being installed. b) Install the tool (B) on pump.c) Put the grooves (9) in bonnet and barrel in alignment with the groove (10) in pump gear. The groove must be in alignment with the center of these grooves. Put the pump in position so notches are in alignment with the guide pins in housing bore. Install the pump in its correct position in housing. d) Install the seal and bushing (11). Push down on tool (B), and tighten bushing by hand until the bushing is even with top of housing. If installation of the bushing cannot be made this far by hand, remove it. Remove pump, put components in alignment again and install the bushing again.
If installation of pump is correct, bushing can be tightened by hand until it is even with face of pump housing.
e) After installation of each pump, check the rack travel as follows: Move the clamp (8) away from the end of rack. Check rack travel with gauge (7). If installation of the pump gear has been correct respective to rack, total rack travel must be .800 in. (20.32 mm). If you can not get total rack travel, remove the pump, put components in alignment again and again install pump. f) Remove the tool (B) and tool (E). Install tool (A) and turn retaining bushing to a torque of 150 10 lb. ft. (20.7 1.4 mkg). Remove tool (A). Install the washers and protection caps for fuel injection pumps.end by: a) connection of governor to fuel injection pump housing