840922 Volvo.Penta Instrument panel

start by:a) remove governor from fuel injection pump housing 1. Remove the fuel injection pumps as follows: a) Remove the protection cap and washer (1). b) Install wrench (A) and remove bushing (2) from housing.c) Remove the seal (3). d) Install extractor (B).e) Lift the fuel injection pump out of the housing.f) Remove the spacer (4). Keep the spacers (4) and pumps together, and put a mark on them as to their location in the fuel injection pump housing.2. Disassemble the fuel injection pump as follows: a) Remove the bonnet (5), ring (6), spring (7) and check valve (8) from the barrel (9).b) Remove the plunger (10), washer (11) and spring (12) from the barrel (9).
During disassembly and assembly of fuel injection pumps, do not cause damage to plunger surfaces. The barrel and plunger are exactly fitted, and the parts can not be changed with other barrels or plungers.
3. Remove the rack (13).4. Remove the lifters (14). Put identification on the lifters and keep them together with their respective pump and spacers. 5. Remove the camshaft plate (15), bolt and lock. 6. Remove the spring (16) and the gear (17) from the camshaft. 7. Remove the camshaft (19). 8. Install tool group (C) and remove the camshaft bearings from the housing of injection pumps.9. Remove the two bearings (18) from the fuel injection pump housing.Assemble Fuel Injection Pump Housing
1. Install the camshaft bearings in the housing of injection pumps with tool group (C). 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. Install the two rack bearings in the housing of injection pumps with tooling (D). Install the bearing toward governor end of housing so it will be .195 .005 in. (4.95 0.13 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 SAE 30 engine oil on camshaft. Install the camshaft in fuel injection pump housing. 4. Install the governor drive gear (1) and spring (2) in position on the camshaft. Install the camshaft 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 housing of injection pumps so the groove (slot) in rack is toward governor end of housing.6. Install the spacers in their respective positions in housing. When installing new lifters and pumps, it is necessary to make adjustment of the fuel pump timing. See FUEL INJECTION PUMP TIMING DIMENSION SETTING, OFF ENGINE in TESTING AND ADJUSTING.7. Assemble the fuel injection pumps as follows: a) Put clean fuel oil on all parts.b) Install the spring, washer and plunger in the barrel.c) Install the spring, check valve, bonnet and ring on the barrel.
Do not install fuel injection pumps until the rack has been put in the center position.
8. Put the rack in center position with tooling (E) as follows: a) Install location fixture (6) on the fuel injection pump housing.b) Install the gauge (7). Move the gauge (7) to zero. Push the rack (5) against the gauge. c) Install the clamp (8) on pump housing as illustrated. This will keep the rack in the center while installing the fuel injection pumps.9. With the rack in the center, install the fuel injection pumps as follows: a) Turn the camshaft until cam of camshaft is in DOWN position for installation of pump. b) Install the extractor (B) on pump.c) Look down the pump and put the notches (9) in bonnet and barrel in alignment with the groove (slot) (10) in pump gear segment. The groove (slot) (10) must 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 bushing (11). Push down on extractor (B), and tighten bushing by hand until the bushing is even with top of housing. If installation of the bushing cannot be made this far by hand, remove it. Remove pump, put components in alignment again and install the bushing again.
Do not force bushing even with face of pump housing using a wrench. If installation of pump is correct, bushing can be tightened by hand until it is even with face of pump housing.
e) After installation of each pump, check the rack travel as follows: Move the clamp (8) away from the end of rack. Check rack travel with gauge (7). If installation of the pump gear has been correct respective to rack, total rack must be about .800 in. (20.3 mm). If total rack travel cannot be made, remove the pump, put components in alignment, and install pump again. f) Remove extractor (B) and tooling (E). Install wrench (A) and tighten retaining bushing to 150 10 lb.ft. (205 14 N m). Remove wrench (A). Install the felt washers and protection caps.end by:a) install governor on fuel injection pump housing