3854230 Volvo.Penta Module

WRENCH INSTALLED
1. 8S2243 Wrench. 2. Protective cap. 3. Retaining bushing.c. Install 8S2244 Extractor (4).d. Remove retaining bushing (3) and wrench (1).e. Remove the seal and lift the fuel injection pump out of the housing. Keep components together and identified as to location.
REMOVING PUMP
4. 8S2244 Extractor.4. Remove the rack (6) and rack bumper spring (5).
REMOVING RACK
5. Rack bumper spring. 6. Rack.5. Remove the lifters. Identify the lifters and keep them with their respective pumps.
REMOVING PLATE ASSEMBLY
7. Retaining bolt. 8. Plate assembly. 9. Gear assembly.6. Remove the camshaft gear assembly retaining bolt (7) and lock. Remove the plate assembly (8) and camshaft gear assembly (9).7. Remove the camshaft retaining plate, bolts and locks. Remove retaining plate (10).
REMOVING RETAINING PLATE
10. Retaining plate.8. Remove the camshaft (11).
REMOVING CAMSHAFT
11. Camshaft.
REMOVING BEARINGS
12. 8S2241 Camshaft Bearing Removal and Installation Group.9. Use the 8S2241 Camshaft Bearing Removal and Installation Group (12) to remove the camshaft bearings from the fuel injection pump housing.Assemble Fuel Injection Pump Housing
1. Use the 8S2241 Camshaft Bearing Removal and Installation Group (12) to install the camshaft bearings in the fuel injection pump housing.
INSTALLING BEARINGS
12. 8S2241 Camshaft Bearing Removal and Installation Group. The front and rear bearings must be line bored after installation. To line bore the bearings, See Special Instructions Form GMG00672.2. Lubricate the camshaft with engine oil (SAE 30). Install camshaft (11) in fuel injection pump housing.
INSTALLING CAMSHAFT
11. Camshaft.3. Position the camshaft retaining plate (10) and install retaining bolts and locks.
INSTALLING RETAINING PLATE
10. Retaining plate.4. Install the camshaft gear assembly (9), plate assembly (8), retaining bolt (7), and lock.
INSTALLING PLATE ASSEMBLY
7. Retaining bolt. 8. Plate assembly. 9. Gear assembly.
INSTALLING RACK
5. Rack bumper spring. 6. Rack.5. Install the lifters in their respective locations in the fuel injection pump housing. Lubricate the rack generously with clean fuel oil, and install rack (6) with timing pin slot in rack toward front of housing. Install the rack bumper spring (5). If new lifters and pumps are to be installed, it will be necessary to check and/or adjust the fuel pump timing dimension. See FUEL PUMP TIMING DIMENSION SETTING-OFF ENGINE in the TESTING AND ADJUSTING section of the Service Manual.6. The rack must be centered to install the fuel injection pumps. To center the rack, remove rack cover (13) and pull the rack toward the governor end of the housing until centering slot in rack is beyond centering pin hole. Insert an 8S2291 or FT887 Timing Pin (14) in the timing hole. Push the rack toward front of housing until slot in rack is against the timing pin. The rack is now centered.
RACK COVER
13. Rack cover.
TIMING PIN INSTALLED
14. 8S2291 or FT887 Timing Pin.7. With the rack centered, install the fuel injection pumps as follows: a. Rotate the camshaft until camshaft lobe for pump to be installed is down or at lowest point.b. Install the 8S2244 Extractor on the pump.c. Sight down the pump and align notches in bonnet and barrel with pump gear segment center tooth.d. Position the pump so the notches in bonnet and barrel align with the dowels in the housing and the pump gear segment center tooth aligns with the center notch in the rack. Install the pump in its respective position in the housing.e. Install the seal and retaining bushing. Apply a downward force (by hand) to the extractor and tighten the retaining bushing by hand (finger tight only) until the top of the retaining bushing threads are flush with the top of the housing. If the retaining bushing can not be installed this far by hand, remove it. Remove pump, realign components and install again.
Do not force the top of the bushing threads flush with the top of pump housing by using a wrench. If pump is installed correctly, retaining bushing can be finger tightened flush with top of housing.
f. After each pump is installed, check total rack travel in the following manner: Install 9S225 Bracket Assembly (16) on the housing, install 3S3269 Contact Point (17) on 8S2283 Dial Indicator (15) and install the indicator in 9S225 Bracket Assembly (16). Zero the dial indicator. Do this by moving the indicator back and forth within the mounting bracket until the revolution counter lies between the red zero and black zero. Tighten the dial indicator retaining bolt. Now place the zero on the large dial under the indicator large hand by rotating the dial face. Remove the timing pin and check the total rack travel. Total rack travel should be approximately .624 in. (15.85 mm). A pump installed one tooth off will reduce rack travel approximately .100 in. (2.54 mm). If total rack travel can not be obtained, remove the pump, realign components, and again install pump.
CHECKING RACK TRAVEL
15. 8S2283 Dial Indicator. 16. 9S225 Bracket Assembly. 17. 3S3269 Contact Point.g. After each pump is installed correctly remove the extractor. Install the 8S2243 Wrench and tighten the retaining bushing to 100 10 lb. ft. (13.8 1.4 mkg). Remove the wrench and install the protective cap.8. After all pumps have been installed. Install governor to fuel injection pump housing.9. Install fuel injection pump housing and governor on the engine as a unit.10. Adjust governor and set the rack. See the topics GOVERNOR ADJUSTMENTS and FUEL RACK SETTING in the TESTING AND ADJUSTING section of the Service Manual.