3825027 Volvo.Penta Insert

start by: a) separation of governor from fuel injection pump housing1. Remove the fuel injection pumps using the following method: a) Remove the cap and felt washer (1). b) Install wrench (A) and loosen the retaining bushing (2) from housing. c) Install extractor (B).d) Remove retaining bushing (2) and wrench (A).e) Remove the seal (3).f) Lift the fuel injection pump out of the housing.g) Remove spacer (4). Put identification on spacers (4) and pumps as to their location so they can be installed back into their original positions in pump housing.2. Disassemble fuel injection pumps using the following method: a) Remove bonnet (5), ring (6), spring (7), and check valve (8) from barrel (9).b) Remove plunger assembly (10), washer (11), and spring (12) from barrel (9).
During disassembly and assembly of fuel injection pumps, use much care to prevent damage to the surfaces of plunger assemblies. The barrel and plunger assemblies have a special fit with each other, and are not to be used with other barrels or plunger assemblies.
3. Remove the rack (13).4. Remove lifters (14). Put identification on lifters so they may be installed back into their original positions in housing. 5. Remove the camshaft retaining plate (15), bolt, and lock. 6. Remove the spring (16) and the gear assembly (17) from the camshaft. 7. Remove the camshaft (19). 8. Install tool setup (C) and remove the camshaft bearings from the fuel injection pump housing.9. Remove the two rack bearings (18) from the fuel injection pump housing.Assemble Fuel Injection Pump Housing
1. Use tool group (C) to install the camshaft bearings in the fuel injection pump housing. Install the bearing toward governor end of housing so the oil hole in bearing is in alignment with oil hole in housing. Install the two bearings on each end of the housing so the edge of bearing will be even with end of housing. 2. Use tool setup (D) to install the two rack bearings in the fuel injection pump housing. Install the bearing toward governor end of housing so it will be .195 .005 in. (4,953 0,127 mm) below end of housing. Install the rack bearing at the other end of housing so it will be even with face of pump housing. 3. Put clean engine oil on the camshaft. Install the camshaft in the fuel injection pump housing. 4. Put the governor drive gear (1) and spring (2) in position on camshaft. Install the camshaft retaining plate (3), bolt, and lock. 5. Install the lifters (4) in their respective positions in housing. Put clean fuel oil all over the rack. Install rack (5) in fuel injection pump housing so slot (groove) in rack is toward governor end of housing.6. Install the spacers in their respective positions in housing. If new lifters and pumps are to be installed, an adjustment must be made to the fuel pump timing dimension. See FUEL INJECTION PUMP TIMING DIMENSION SETTING - OFF ENGINE in TESTING AND ADJUSTING.7. Assemble the fuel injection pumps using the following method: a) Put clean fuel oil on all parts of the fuel injection pumps.b) Install the spring, washer, and plunger assembly into the barrel.c) Install the spring, check valve, bonnet, and ring on the barrel.
Do not try to install the fuel injection pumps in the housing until the rack has been put in center position.
8. Use tool setup (E) to put the rack in center position as follows: a) Install the locating fixture (6) on the fuel injection pump housing.b) Install the rack setting gauge (7).c) Put the gauge (7) in the zero reading position.d) Push the rack (5) against the gauge (7). e) Install clamp (8) on housing as shown in the illustration. Clamp (8) will keep the rack in the center position during installation of the fuel injection pumps.9. With the rack in center position, install the fuel injection pumps as follows: a) Turn the camshaft until lobe of camshaft is down for pump being installed. b) Install extractor (B) on the pump.c) Look down the pump and put the notches (9) in bonnet and barrel in alignment with the slot (10) in pump gear segment. The slot (10) should be in alignment with the center of notches (9). Put the pump into position so that notches (9) are in alignment with the guide pins in bore of housing. Install the pump in its respective position in the pump housing. d) Install the seal and retaining bushing (11). Push down on extractor (B), and tighten the bushing by hand (finger tight only) until the bushing is even with top surface of housing. If bushing cannot be installed this far by hand, remove it. Remove pump. Put the parts in alignment and install pump again.
Do not make bushing even with face of housing by using a wrench. If pump has been installed correctly, the bushing can be tightened with the fingers until even with face of housing.
e) After all pumps have been installed, check the rack travel as follows. Move clamp (8) away from end of rack. Use gauge (7) to check the rack travel. If pump gear has been installed correctly in relation to rack, the total rack travel should be about .800 in. (20,3 mm). If total rack travel can not be made, remove the pump; put components in alignment, and install pump again. 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 protection caps.end by: a) connection of governor to fuel injection pump housingb) install fuel injection pump housing and governor as a unitc) make adjustments to rack and governor (See FUEL RACK SETTING AND GOVERNOR ADJUSTMENTS in TESTING AND ADJUSTING)