3803711 Volvo.Penta Injection pump, exch

START BY:a) remove electric starting motorb) remove fuel injection lines No. 1 piston at top center (TC) on the compression stroke is the starting point for all timing procedures. The engine is seen from the flywheel end when direction of crankshaft rotation is given. 1. Install tooling (A) on flywheel housing as shown.2. To find top center compression stroke for No. 1 piston, first turn the flywheel clockwise (opposite the direction of engine rotation) approximately 30 degrees. This procedure is to remove all play from the timing gears.3. Turn the flywheel counterclockwise until a 3/8"-16 NC bolt (1) can be installed in the flywheel through the hole in the flywheel housing. The No. 1 and No. 4 pistons are now at top center position.
If you go past the bolt hole you must start over with Step 2.
4. Remove the valve cover.5. To see if the No. 1 piston is on the compression stroke, look at the valves of the No. 1 cylinder. The valves will be closed if No. 1 cylinder is on the compression stroke. You must be able to move the rocker arms up and down with your hand.6. If No. 1 piston is not on the compression stroke, remove the 3/8"-16 NC bolt (1) and turn the flywheel 360° counterclockwise. Install the 3/8" bolt as before. The No. 1 piston is now at top center (TC) on the compression stroke. 7. To install tool (B) in the fuel injection pump housing, remove the 3/8"-16 NC bolt from the flywheel and turn the flywheel approximately 30° clockwise.8. Remove bolt and install tool (B) in the governor housing. Turn the flywheel slowly in a counterclockwise direction until pin (8) goes into the notch in the camshaft.9. Put the 3/8"-16 NC bolt in the timing hole in the flywheel housing. If the bolt can be installed in the hole in the flywheel, the timing on the fuel injection pump is correct. 10. Remove bolts (2) and right hand guard assembly (3).11. Remove fan belts from alternator and fan pulleys. 12. Remove nuts (5) and cover (4) from the front of the timing gear cover. 13. Remove bolt (6) and washer (7) that hold the drive gear to the fuel injection pump. 14. Install tooling (C) to loosen the drive gear from drive sleeve. 15. Remove bolt (12) and clamps (13) that fasten the turbocharger inlet and drain lines together.16. Remove bolts (8) and (11) and gaskets that fasten oil tube assemblies (9) and (10) to the turbocharger. Remove oil tube assembly (9) from engine. 17. Remove two bolts (14) and loosen bolt (17) that fastens bracket (15) to the fuel injection pump. Remove tube assembly (10) and adapter from the cylinder block. 18. Remove bolt that fastens the breather tube bracket (19) to the fuel pump.19. Remove three nuts (18). Remove the fuel injection pump housing and governor (16).Install Fuel Injection Pump Housing And Governor
1. Inspect the O-ring seal for damage in the transfer pump housing (2) make a replacement if necessary.2. Put the fuel injection pump housing and governor (1) in position on the engine and against the timing gear plate. 3. Install three nuts (3) that hold the fuel injection pump housing to the timing gear plate. Do not tighten nuts until the adapter and lower turbocharger oil tube assembly is installed.4. Install breather tube bracket (4) in position on the fuel injection pump. 5. Inspect O-ring seals (7) on adapter (8) and make a replacement if necessary.6. Put adapter (8) and tube assembly (5) in position and install two bolts to hold the adapter to the block. Install gasket and two bolts to hold tube assembly (5) to the turbocharger. Tighten three nuts that fasten the fuel injection pump housing and governor to the timing gear plate. Tighten bolt on bracket (6). 7. Put oil tube assembly (9) in position and install gasket and two bolts to fasten tube to the turbocharger. Install clamps that fasten tube assemblies (5) and (9) together.
Typical Example8. Put drive gear in position on the fuel injection pump shaft and install washer (10) and bolt (11) finger tight. Install tooling (C) on drive gear.9. Put a torque wrench on tool (C) and give it a torque of 45 to 50 lb.ft. (60 to 70 N m). While this torque is held, tighten the drive gear bolt to a torque of 110 5 lb.ft. (149 7 N m). Remove pin (B) from the fuel pump and the 3/8"-16 NC bolt from the flywheel.
Typical Example10. Turn the engine flywheel two complete revolutions with tooling (A). If the 3/8"-16 NC bolt goes in the hole in the flywheel when the timing pin is installed in the notch in the camshaft, the timing is correct. 11. Put gasket and cover (12) in position on the timing gear cover. Install nuts. Tighten nuts to a torque of 17 3 lb.ft. (23 4 N m).12. Install vee belts on the pulleys. Make an adjustment of the vee belts. See INSTALL ALTERNATOR. 13. Install right hand fan guard (13) in position on the radiator. 14. Remove tooling (A) and the 3/8"-16 NC bolt (14) from the flywheel housing.END BY:a) install fuel injection linesb) install electric starting motor