3803652 Volvo.Penta Injector

start by: a) remove fuel injection pump housing and governorb) remove governor1. Remove the fuel injection pumps as follows: a) Remove the rack centering pin cover (1). Move the rack until the centering pin can be depressed. Install the pin cover so the edge of the cover holds the pin down. Hold the rack toward the driven end of the pump housing. b) Remove the protective cap and felt washer (2).c) Install wrench (A) and remove retaining bushing (3).d) Remove seal (4).e) Install extractor (B) and lift the fuel injection pump out of the housing.
Do not attempt to remove the fuel injection pumps without the rack centering pin installed and the rack held toward the driven end of the pump housing.
f) Remove spacer (10). Keep the spacers and pumps together, and identified as to their location in the fuel injection pump housing.2. Disassemble the fuel injection pumps as follows: a) Remove bonnet (5), ring (8), spring (7), and check valve (6) from barrel (9).b) Remove plunger assembly (11), washer (12), and spring (13) from barrel (9).
While disassembling and assembling fuel injection pumps, exercise considerable care to prevent damage to plunger surfaces. The barrel and plunger assemblies are matched, and the individual parts are not interchangeable with other barrels or plunger assemblies.
3. Remove the rack centering pin cover, spring and pin.4. Remove the rack from the fuel injection pump housing. 5. Remove lifters (14). Keep the lifters identified and together with their respective pumps and spacers. 6. Remove the camshaft retaining bolt, lock and retaining plate (17).7. Remove spring (15) and gear assembly (18) from the camshaft. 8. Remove the fuel injection pump camshaft (19) from housing. 9. Using tool group (C), remove the camshaft bearings from the fuel injection pump housing.10. Remove two rack bearings (16) from the fuel injection pump housing.Assemble Fuel Injection Pump Housing
1. Using tool group (C), install the camshaft bearings in the fuel injection pump housing. Install the bearing in governor end of housing so that the oil hole in bearing is aligned with oil hole in housing. Install the two end camshaft bearings flush with their respective ends of fuel injection pump housing. 2. Using tool setup (D), install the two rack bearings in the fuel injection pump housing. Install the bearing in governor end of housing so that it will be recessed .195 .005 in. (4,95 0,13 mm) from face of housing. Install the rack bearing in accessory drive end of housing so that it will be flush with face of fuel injection pump housing.3. Lubricate the camshaft with clean SAE 30 engine oil. Install the camshaft in fuel injection pump housing. 4. Position governor drive gear (1) and spring (2) on the camshaft. Install camshaft retaining plate (3), bolt, and lock. 5. Install lifters (4) in their respective positions in housing. Lubricate the rack generously with clean SAE 30 engine oil. Install the rack in fuel injection pump housing with the slot in rack toward the driven end of pump housing.6. Install the rack centering pin, spring and cover. Depress the pin and position the edge of the cover over the pin to hold it down. 7. Install the spacers in their respective positions in housing. If new lifters and pumps are to be installed, it will be necessary to set the fuel pump timing dimension. See FUEL INJECTION PUMP TIMING DIMENSION SETTING-OFF ENGINE in TESTING AND ADJUSTING.8. Attach the dial indicator, from tool group (E) to the pump housing as shown. Center the dial by moving it toward the driven end of the pump housing and zero the dial indicator.9. Assemble the fuel injection pumps as follows: a) Lubricate all parts generously with clean fuel oil.b) Install the spring, washer, and plunger in the barrel.c) Install the spring, check valve, bonnet, and ring on the barrel.
Do not attempt to install fuel injection pumps until the rack has been centered.
10. With the rack centered, install the fuel injection pumps as follows: a) Rotate the camshaft until lobe of camshaft is down for pump to be installed.b) Install extractor (B) on the pump.c) Sight down the pump, and align notches (5) in bonnet and barrel with slot (6) in pump gear segment. The slot should be in line with the center of these notches. Position the pump so the notches align with the guide pins in housing bore. Install the pump in its respective position in housing. d) Install the seal and retaining bushing (7). Apply a downward force to extractor (B), and tighten the bushing by hand (finger tight only) until bushing is flush with top of housing. If the bushing can not be installed this far by hand, remove it. Remove pump, realign components and install again.
Do not force bushing flush with face of pump housing by using wrench. If pump has been properly installed, bushing can be finger tightened flush with face of pump housing.
e) After each pump has been installed, check the rack travel in the following manner. Swing rack centering pin (8) cover aside and allow centering pin to come up. Using dial indicator (E) check the rack travel. If the pump gear has been installed correctly with respect to the rack, total rack travel should be approximately .800 in. (20,32 mm). If total rack travel cannot be obtained, remove the pump, realign components and reinstall pump. f) Remove extractor (B) and tool setup (E). Install wrench (A), and tighten retaining bushing to 150 10 lb. ft. (20,7 1,4 mkg). Remove wrench (A). Install the felt washers and protective caps.end by: a) install governorb) install fuel injection pump housing and governor as a unitc) adjust governor and set rack (See GOVERNOR ADJUSTMENTS and FUEL RACK SETTING in TESTING AND ADJUSTING)