844293 Volvo.Penta Key

Start By:a. remove fuel injection lines
At operation temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
Release the pressure in the cooling system by slowly loosening the filler cap on the radiator. Drain the coolant from the radiator and oil from the hydraulic oil cooler.1. Drain radiator below level of the aftercooler. 2. Remove two bolts (2) that hold water line elbow (1) to aftercooler. Remove water line (3) from front elbow. 3. Disconnect fuel and air lines (4) from the fuel injection pump housing. Put caps on fuel line openings. 4. Remove bolts (6) and (7) that hold bracket (5) to fuel injection pump housing and cylinder head. Remove bracket (5). Remove bolts (8) on each side of the pump. 5. Remove bolts and cover (11). Retainer (10) is free to fall into the housing when bolts (9) are removed.6. Remove the cover and remove bolts (9) that hold the automatic timing advance to the end of the fuel pump camshaft. 7. Fasten tooling (A) and a hoist to the fuel injection pump housing and governor. Remove fuel injection pump housing and governor (11). Weight of the unit is 66 kg (145 lb).Install Fuel Injection Pump Housing & Governor
1. Remove the plug from the front of the injection pump housing. Install tool (B) (as shown) through the hole in the pump housing and into the timing notch in the fuel injection pump camshaft. 2. Put a small amount of 5P0960 Multipurpose Type Grease on O-ring seal (2).3. Fasten tooling (A) and a hoist to fuel injection pump and governor (1). Put the fuel injection pump housing into position on top of the engine. 4. Put retainer (4) and bolts (3) in position on the automatic timing advance. Tighten the bolts evenly to a torque of 70 N m (50 lb ft). Remove tool (B) and tighten the bolts evenly to a torque of 135 7 N m (100 5 lb ft).5. Use tool (C) to turn the engine in a counterclockwise direction (as seen from the flywheel end of the engine) until the no. 1 piston is at top center on compression stroke. install timing bolt (1) in flywheel. See Finding Top Center Compression Position For NO. 1 Piston in Systems Operating Testing And Adjusting.6. If timing is correct, tool (B) will go into the notch in the fuel injection pump camshaft and the timing bolt will turn freely into the threaded hole in the flywheel. if timing is not correct, remove tool (B) and the timing bolt and do the following procedure:a. Make sure tool (B) is removed from the fuel injection pump camshaft. Loosen four bolts which hold the automatic timing advance unit on the fuel pump camshaft.b. Tighten the bolts with fingers until there is a small amount of friction (slight drag) between the retainer and the timing advance unit. this will prevent movement (backlash) when the gears are turned to the correct timing.c. Use tool (C) to turn the engine in a counterclockwise direction (as seen from the flywheel end) until tool (B) can be installed in the fuel injection pump camshaft.d. Use tool (C) to turn the engine in a clockwise direction (as seen from the flywheel end) a minimum of 30 degrees to remove the movement (backlash) in the timing gears.e. Use tool (C) to turn the engine in a counterclockwise direction (as seen from the flywheel end) until the No. 1 piston is at top center compression stroke. Install the timing bolt in the flywheel.f. Tighten the bolts that hold the automatic timing advance to a torque of 25 N m (20 lb ft). Remove tool (B) from the fuel injection pump camshaft.g. Tighten the bolts to a torque of 135 7 N m (100 5 lb ft) Remove the timing bolt (1) from the flywheel.7. Turn the engine two complete revolutions and check the timing again. If tool (B) will not go into the notch of the fuel injection pump camshaft, do Steps a through again. 8. Install bolts (6) on each side of the fuel injection pump housing.9. Install bracket (5) and install the bolts that hold it to the cylinder head and pump housing. Tighten the bolts that hold bracket (5) to the cylinder head to a torque of 43 7 N m (32 5 lb ft). 10. Connect the fuel and air lines (7) to the fuel injection pump housing. 11. Install water line and elbow (8) on aftercooler. Install two bolts that hold elbow on aftercooler. 12. Install the gasket and cover (9) on the automatic timing advance housing.13. Check coolant in the cooling system.End By:a. install fuel injection linesDisassemble Fuel Injection Pump Housing & Governor
a. remove fuel injection pump housing and governorb. remove fuel ratio control 1. Remove fuel shutoff solenoid (1) from housing. 2. Remove five bolts (4) and remove cover (5). Remove bolt (2) then remove cover (3) from high and low idle screws. 3. Remove bolt (7) and remove large cover assembly (6). Remove gasket (8). Be careful not to drop strainer assembly out of bottom of cover assembly. Remove strainer after cover assembly is removed. 4. Bend locks (9) back, then remove four bolts (11) and lever (10). 5. Remove shaft (13) and washer (12) from large cover assembly. 6. Remove two bearings and two seals (14) from the cover assembly. 7. Remove insulator (15) from cover assembly. 8. Remove bolt (18) from stop collar (16). Remove spring (17) from below collar. 9. Remove bolts (20), then remove governor housing (19). 10. Put a mark on low and high idle screws (21) and make a note of each turn