3803515 Volvo.Penta Injection pump

1. Remove the engine side cover. Disconnect the governor control linkage (4) from the governor.2. Remove the oil supply line (1) for the turbocharger.3. Remove the oil drain line (3) for the turbocharger.4. Remove the crankcase breather pipe (2).5. Disconnect the injection lines (5) from the housing of injection pumps.6. Loosen the injection lines (5) for fuel from the valves for injection of fuel.7. Put caps over pumps in pump housing.8. Remove the bolts (7) that fasten the housing of injection pumps to the housing of accessory drive.9. Remove the two bolts (6) that hold the housing of injection pump to the elbow. 10. Remove the housing of injection pumps and governor as a unit. Weight of the unit is 50 lb. (23 kg).Install Fuel Injection Pump Housing And Governor As A Unit
1. Turn crankshaft until No. 1 piston is at top center on compression position. See LOCATING TOP CENTER COMPRESSION POSITION FOR NO. 1 PISTON in TESTING AND ADJUSTING. Install the timing fixture plate (A) on rear face of the housing of accessory drive. 2. If plate (A) can be installed with dowels in housing in alignment with dowel holes in plate, the accessory drive shaft is in correct timing position. Do Step 7 next. If plate (A) can not be installed, do steps 3 through 9.3. Remove the small cover from front of timing gear cover. Remove the nut and washer that fasten the timing gear to the shaft. 4. Use tool setup (B) to make a separation between the gear and shaft. Turn the shaft until plate (A) can be installed with dowels and holes in alignment.5. Install the washer on shaft so the outside diameter of washer is against the gear. Install and tighten the nut to 100 10 lb.ft. (13,8 1,4 mkg).6. Install the cover on timing gear cover.7. Remove timing fixture plate (A) from housing. Put housing of injection pumps and governor into position, and install bolts. 8. Remove caps from injection pumps. Put lines into position, and tighten nuts (2) to 30 5 lb.ft. (4,1 0,7 mkg).9. Install the oil supply line and the oil drain line for the turbocharger.10. Install the crankcase breather pipe (3). Connect the control linkage (1) to governor. Install engine side cover.Separation Of Governor From Fuel Injection Pump Housing
start by: a) remove fuel injection pump housing and governor as a unit 1. Remove the cover (1).2. Remove the screw (2) for the rack stop collar.3. Remove rack stop collar (3).4. Remove the bolts (4) that hold the governor to the housing of injection pumps. 5. Remove the governor housing (5).6. Remove the governor spring and seat assembly from the guide in housing (5).7. Remove the washer type spring (6) from bolt.8. Remove the three bolts (7) and lock that hold the cylinder and weight assemblies (8) to the housing of injection pumps.9. Pull the cylinder and weight assemblies straight out until they are free of dowels. 10. Slide the cylinder and weight assemblies to the side to free the piston from rack (9).Connection Of Governor To Fuel Injection Pump Housing
1. Put the cylinder and weight assemblies (1) in position on the housing of injection pumps so the piston (2) is in correct location on the rack (3).2. Push the cylinder and weight assemblies onto the location dowels. 3. Install the three bolts (4) and lock.4. Install the washer type spring (5) on bolt (6).5. Put the seat assembly and governor spring on guide in governor housing. The washer type spring (5) should be installed so the inside diameter of spring will be against the guide in governor housing (7).6. Put the governor housing (7) in position on housing of injection pumps, and install the bolts. 7. Install the rack stop collar (8) on bolt (6).8. Put the idle screw cover (10) in position on the governor housing so the dowel (11) in housing is engaged with slot (12) in the rack stop collar.9. Install the bolts that fasten the idle screw cover to the governor housing.end by: a) install fuel injection pump housing and governor as a unitb) make an adjustment to the rack and governor (See FUEL RACK SETTING AND GOVERNOR ADJUSTMENTS in TESTING AND ADJUSTING)