844442 Volvo.Penta Injection pump

start by:a) remove fuel injection lines1. Remove the hood. Remove the panel assembly from the left side of the rear frame.2. Turn the fuel valve to the "OFF" position. The valve location is on the fuel tank. 3. Disconnect rod assembly (3) from the governor control lever.4. Disconnect hose assembly (5) from the fuel injection pump housing. Disconnect hose assembly (4) from the fuel filter base.5. Remove fuel line (1) and disconnect fuel line (2) from the fuel ratio control.6. Remove the clip used to hold drain hoses in position at the cylinder block below the alternator. 7. Remove timing pin (6) from storage hole (7). Use the bolt that holds the crankshaft pulley to turn the crankshaft clockwise as seen from the front of the engine. Turn the crankshaft until pin (6) can be installed in the groove (slot) of the fuel injection pump camshaft. Tool (A) can be used to turn the crankshaft. If tool (A) is used, remove the electric starting motor and install tool (A) in the flywheel housing.8. Remove the plug from the flywheel housing. Install a 3/8"-16 NC x 2 1/2" bolt (8) into the threaded hole of the flywheel.
Never turn the crankshaft counterclockwise to install the bolt in the flywheel. If the crankshaft is turned counterclockwise, the gear clearance (backlash) can cause the engine to be out of time when the fuel injection pump housing and governor are installed.
9. Remove the left hand fan guard (9) from machine.10. Loosen the bolts that hold the alternator in position and remove vee belts (10) from the alternator pulley. 11. Remove cover (11) and gasket from the timing gear cover.12. Remove the bolt and washer that hold the drive gear to the fuel injection pump camshaft. Install tooling (C) on the end of the bolt. Install and tighten the bolt, washer and tooling (C) to hold the sleeve on the end of the fuel injection pump camshaft. 13. Install tooling (B) on the drive gear. Tighten the center bolt of tooling (B) until the drive gear is loose. Remove tooling (B), the bolt and washers. The drive gear will stay in the timing gear cover. 14. Remove bracket (15), turbocharger oil lines (14) and adapter (13).15. Remove the nuts (12) and bolt that hold the fuel injection pump housing and governor to the timing gear plate, and remove the fuel injection pump housing and governor.Install Fuel Injection Pump Housing And Governor
1. Make sure the timing pin is installed in the groove (slot) of the fuel injection pump camshaft. 2. Inspect the O-ring seal for the fuel transfer pump. Install a new seal if needed. Put clean engine oil on the seal. Put the fuel injection pump housing and governor assembly (1) in position on the engine. Install the nuts and bolt that hold it in place. 3. Put clean oil on the adapter O-ring seals, and install adapter (2) and bracket (3) in position on engine. 4. Install turbocharger lines (4) between the turbocharger and adapter.5. Install the washer and bolt that hold the pump drive gear to the camshaft. Tighten the bolt finger tight only.
TYPICAL EXAMPLE6. Put a force of approximately 50 lb.ft. (70 N m) on the drive gear with tool (A). Tighten the bolt to a torque of 110 5 lb.ft. (149 7 N m).7. Check the timing to make sure it is correct. a) Remove the timing pin from the pump camshaft and the bolt from the flywheel.b) Turn the crankshaft clockwise (as seen from the front of the engine) approximately 1/2turn. Install the timing pin again.c) While the crankshaft is turned clockwise (as seen from the front of the engine), push on the timing pin until it slides into the groove (slot) in the pump camshaft.d) Install the bolt in the flywheel. The timing is correct when the bolt is installed in the flywheel and the timing pin is installed in the groove (slot) in the pump camshaft.e) Remove the timing pin and the bolt. Install the plug in the flywheel housing. Install the bolt in the cover on the pump housing. 8. Put gasket and cover (5) in position on the timing gear cover. Install nuts and tighten to a torque of 20 5 lb.ft. (25 7 N m). 9. Put vee belts (7) in position. Make an adjustment. See INSTALL ALTERNATOR.10. Install fan guard (6) on the radiator. 11. Connect the rod assembly (10) to the governor control lever.12. Connect hose assembly (12) to the fuel injection pump housing. Connect hose assembly (11) to the fuel filter base.13. Connect fuel line (9) to the fuel ratio control. Install fuel line (8), fuel filter and the water separator.14. Fasten the clip that holds the drain lines below the alternator.15. Remove the bolt from the flywheel and install the plug in the flywheel housing.16. Install the panel assembly and hood on the rear frame.17. Turn the fuel valve to the "ON" position.end by: a) install fuel injection lines