478606 Volvo.Penta Injector

Start By:a. remove fuel injection linesb. remove air inlet manifoldc. remove fan drive 1. Remove the bolts, and remove adapter (1) from over the tachometer drive shaft. 2. Remove tachometer drive shaft (2) and the washer that hold the drive gear on the fuel injection pump camshaft. 3. Install tool (A), and use it to loosen the drive gear on the fuel injection pump camshaft. Remove tool (A). 4. Disconnect wires (3) from the fuel shutoff solenoid and the wire from the switch.5. Disconnect fuel supply tube (5) from the fuel injection pump housing.6. Remove fuel return tube (4) from the fuel injection pump housing and the engine. 7. Remove two bolts (7), and remove fuel injection pump housing and governor (6) from the engine.Install Fuel Injection Pump Housing And Governor
1. Clean and inspect O-ring seals (1) and (2). Make a replacement of the seals if worn or damaged. 2. Install tool (B) in the fuel injection pump camshaft. Remove the plug from the cover on the fuel injection pump housing, and install tool (A). Use tool (B) to turn the camshaft until timing pin (A) can be pushed into the groove (slot) in the fuel injection pump camshaft. 3. Put fuel injection pump housing and governor (3) in position on the engine. Install the two bolts that hold the unit in position. 4. Remove the starter, and install tool group (C) in the flywheel housing to turn the engine. 5. Install the washer and tachometer drive shaft (4), but do not tighten shaft (4).6. Remove the cap and fitting from the front housing at location (5).7. Install a 5/16"-18 NC bolt (6) 2 1/2 in. long. The cover bolt from hole (7) can be used. Use tool group (C) to turn the crankshaft clockwise (as seen from front of engine) until bolt (6) can be installed in the camshaft gear and is in the center of the timing hole. With timing pin (A) in the groove (slot) in the fuel injection pump camshaft and bolt (6) in the hole in the engine camshaft gear, the timing for the engine is correct. Tighten tachometer drive shaft (4) to a torque of 150 14 N m (110 10 lb.ft.).8. To check the timing, remove timing pin (A) and bolt (6). Turn the crankshaft with tool (C) clockwise (as seen from front of engine) two revolutions, and install the timing pin (A); then bolt (6) back in place. If bolt (6) cannot be installed, the timing is not correct. The procedure must be done again. Do not turn the crankshaft counterclockwise (as seen from the front of the engine) to install bolt (6). The drive gear on the fuel injection camshaft must be loosened to change the timing. 9. Install adapter (8) over the tachometer drive shaft.10. Remove bolt (9) from the camshaft gear, and install it back in its original position in the front housing.11. Install the fitting and cap in the front housing. 12. Remove timing pin (A), and install the plug in the cover on the fuel injection pump housing.