3803586 Volvo.Penta Injector

1. Bend the locks away from bolts (7). Remove bolts (7), the locks and suction bell (8) from the oil pump if necessary.2. Remove two bolts (5) that hold elbow (2) and tube (3) to the oil pump.
Oil pump idler gear (6) is not fastened to the oil pump and can fall off when the oil pump is removed. To prevent injury, always hold the gear on the oil pump when it is removed from the engine.
3. Remove four bolts (1), two locks and two washers that hold the oil pump to the engine. Remove oil pump (4) from the engine.Install Oil Pump
1. Turn the crankshaft until the No. 1 piston is at top center of the compression stroke. See Testing And Adjusting for this procedure. 2. Turn both balancer shafts (1) until the flat part on each shaft is away from the oil pan plate. Install two bolts (2) [3/8" - 16 NC x 51 mm (2 in.) long] through the oil pan plate and into the threaded holes in the balancer shafts. Do not tighten the bolt against the bottom of the holes in the shafts. 3. Install idler gear (8) on the oil pump. Put oil pump (5) in position on the engine as shown. Make sure the oil pump gears are engaged with the balancer shaft gears and the crankshaft gear. Install bolts (6), the washers and locks that hold the oil pump in place.4. Remove bolts (2) from the balancer shafts. Remove the timing bolt from the flywheel. Check to see that the balancer shaft timing is correct. The balancer timing is correct when the holes in the balancer shafts are in alignment with the holes in the oil pan plate, and No. 1 piston is at the top center of the compression stroke.5. Install two bolts (7) that hold elbow (3) and tube assembly (4) to the oil pump.6. Put suction bell (9) and the gasket in position on the oil pump, and install the locks and bolts that hold it in place.END BY:a. install oil panDisassemble Oil Pump
START BY:a. remove oil pump 1. Remove idler gear (2). Remove the bearing from the idler gear with tooling (B).2. Remove suction bell (1).3. Remove the bolt and the washer from the oil pump drive gear. 4. Remove the drive gear from the shaft with tooling (A).5. Remove the key from the pump shaft.6. Remove bolts (3) from the pump body. 7. Remove body (8), two gears (7), the keys and spacer (4) from the pump.8. Remove two shafts (5) and the gears.9. Remove bolts (6), the cover and the pressure relief valve from the body. 10. Remove the bearings from the oil pump body assembly and the scavenge pump body assembly with tooling (B).Assemble Oil Pump
1. Install the bearings in the scavenge pump body assembly with tooling (A) and a press as follows:a. Put bearings (1) in position on the inside of the scavenge pump body assembly with the chamfer on the bearing toward the outside of the pump body. Install the bearing until it is 1.52 mm (.060 in.) below the inside machined surface of the scavenge pump body assembly. Make sure the joints in the bearings are at an angle of 30° 15° from the center line through the bores in the scavenge pump body and toward the outlet passage of the pump. The outlet passage has a cavity between the bearing bores. 2. Install the bearings in oil pump body assembly with tooling (A) and a press as follows:a. Put bearings (2) in position on the inside of the oil pump body assembly with the chamfer on the bearings toward the outside of the pump body. Install the bearings until they are even with the outside of the pump body. Make sure the joints in the bearings are at an angle of 30° 15° from the centerline through the bearing bores and toward the outlet passage of the pump. The outlet passage has a cavity between the bearing bores.3. Check the condition of the relief valve. Check the condition and specifications for all the parts of the oil pump before it is assembled. See Oil Pump in Specifications.4. Put clean engine oil on all the parts of the oil pump. 5. Install pressure relief valve (3), cover (4) and bolt (5) in the oil pump body assembly. 6. Install shaft assemblies (6) in the oil pump body assembly.7. Install spacer (7). Install the key in the shaft assembly.8. Install the two gears on the shaft assemblies. 9. Install scavenge pump body assembly (8) and the bolts that hold it.10. Install key (9), drive gear (11), the washer and bolt (10). Tighten the bolt to a torque of 43 7 N m (32 5 lb. ft.).11. Install the bearing in the idler gear with tooling (A) and a press until it is even with the outside of the gear.12. Install the suction bell on the oil pump. Install the idler gear on the oil pump.
The oil pump must turn freely by hand after it is assembled.
END BY:a. install oil pump