20807510 Volvo.Penta Oil filler cap

1. Remove cotter pin, hook (2), nut, two sleeves, and nut (1) from control cable. 2. Disconnect the three oil lines (3) from safety shutoff.3. Remove four bolts (4) that hold safety shutoff housing (5) to spacer plate.4. Remove safety shutoff housing (5). 5. Remove four bolts (6) and spacer plate (7) from fuel injection pump housing. 6. Remove two bolts (8) and the lock.7. Remove the gear (10) from the adapter.8. Remove the adapter (9) from dowels on the flange assembly. 9. Remove the washer (12).10. Remove flange assembly (11) from fuel injection pump housing. 11. Use tooling (A) to remove bushing from the flange.Install Safety Shutoff
1. Use tooling (A) to install bushing (2) in flange (3). Install the bushing so oil hole (1) is in alignment with oil hole in flange.2. Install flange (3) on end of fuel injection pump housing. Be sure oil hole for flange (3) is installed in alignment with oil hole in housing. 3. Install the washer (5) in the flange.4. Install adapter (4) on dowels of the flange. 5. Install gear (6) so dowels on gear are in alignment with holes in washer and end of injection pump camshaft.6. Install the lock and two bolts that hold gear. 7. Install spacer plate (7) on the dowels. Install the four bolts that hold spacer plate to flange. 8. Install safety shutoff (8) in position on spacer plate and in alignment with gear (6). Install the four bolts that hold safety shutoff to spacer plate.9. Connect the three oil lines.10. Put cable through bracket and install nut, sleeves, nut, hook, and cotter pin.Disassemble Safety Shutoff
start by: a) remove safety shutoff1. Disassemble reset button and piston as follows: a) Remove the screws and bolt (2) that hold cover (1) to housing. Remove the cover. b) Remove pin (5), plunger (7) and spring (6) from cover (1).c) Lift piston (3) out of its bore in housing.d) Remove bearing (4) from cover (1).2. Remove drive assembly as follows: a) Remove two screws (8) that hold adapter assembly (9) to housing. Remove the adapter assembly. b) Remove the snap ring (11) and washer. Remove the gear assembly (12).c) Remove the two dowels (10) that hold gear assembly (12) together. d) Remove the pin (14) that holds gear (15) to shaft. Remove the gear (13) from shaft.e) Remove shaft from the adapter (9).f) Remove the bushings from adapter (9) and gear assembly (12).3. Disassemble carrier and weight as follows: a) Lift carrier (24) from the housing.b) Remove screw (23) from carrier (24). Remember the number of turns needed to remove the screw (16) and use this same number for installation.c) Remove spring (17), weight (18), pin (12) and nut (21). d) Remove gear (19) from shaft (20) with puller (A).4. Remove emergency shutoff button as follows: a) Remove button (27) and spring by loosening screw (26).b) Push plunger (28) down through housing (31).5. Remove plug (30) and gasket from housing.6. Loosen nut (29) and remove gasket and cable assembly (25) as a unit. 7. Remove two pins from collar (35). Remove the collar (35) and spring (33).8. Remove pin (32) and make a separation of nut (34) from cable. 9. Remove two cotter pins (37), washer (39) and springs.10. Push latch (36) out of the way and lift the guide (38) from housing. 11. Remove plug (45) from end of housing.12. Remove ring (41) from the shaft (43). Slide shaft (43) and gear (42) from the housing.13. Remove the pin that holds gear to the shaft. Remove the gear (42) from shaft.14. Remove bearing from the housing.15. The follower shaft (40) is pushed (pressed) into the housing (31). To remove the spring (46), guide (44) and spacer, it is necessary to cause damage to the shaft (40). 16. Remove plug (47) from the housing.17. Remove the spring and latch (release lever).Assemble Safety Shutoff
1. Install latch (release lever) (2) and spring (4) into housing (1).2. It is necessary to install new follower shaft (5).3. Install spacer, guide (3) and spring (6) on shaft (5).4. Push shaft (5) into housing (1) with a press.5. Assemble worm shaft as follows: a) Install bearing into housing (1).b) Install gear (7) on shaft (8) with pin.c) Slide assembled gear and shaft (8) into housing (1) and hold with ring.d) Install plug (9) in end of housing (1). 6. Push latch out of the way and install the guide (11).7. Install the springs (12), washers (13) and cotter pins (14).8. Assemble the cable as follows: a) Connect nut (15) to cable assembly (17) with pin (16).b) Install spring (19) and collar (20) with two pins (23).c) Install cable assembly and gasket (18) into housing and tighten nut (15).d) Install gasket (21) and plug (22) into housing.9. Install emergency shutoff button as follows: a) Push plunger (24) up through housing (1).b) Install the spring (25) and button (26) on the plunger. Tighten the screw (27).10. Assemble carrier and weight as follows: a) Install gear (31) on shaft (32).b) Install nut (33), pin (34) weight (30) and spring (29).c) Install the screws (28) and (35). Tighten screw (28) the same number of turns that was needed to remove it.d) Put a mark (stake) around the screw (28) with a punch and hammer. 11. Install the carrier assembly (36) into the housing.12. Assemble the drive and adapter as follows: a) Install bushing (37), two gears (39), with two dowels (38). b) Install two bushings in the adapter (43).c) Slide shaft (41) into adapter (43).d) Install gear (42) on shaft (41) with pin (40), and make a mark (stake) with punch and hammer.e) Install gear assembly (44) on adapter (43) with washer and snap ring.f) Install drive assembly with two screws that hold adapter (43) to housing (1). 13. Install bearing into cover (46) with tooling (A). 14. Install plunger (5) and spring (49) into cover (46) with pin (47).15. Install piston (45) into bore.16. Install cover (48) with two screws and one bolt that hold