877613 Volvo.Penta Overhaul kit, basic

1. Put the fuel injection pump housing and governor in position on tool (A).2. Remove timing pin (1) from cover (2). Remove the bolt from the cover over the torque spring. Turn the injection pump camshaft until the timing pin can be installed in the groove (slot) in the injection pump camshaft. The timing pin prevents rotation of the injection pump camshaft during removal of the sleeve. 3. Install bolt (B) in the threads of sleeve (4). Tighten the bolt and remove the sleeve.
Do not hit the bolt or the sleeve. Damage to the unit can be the result.
4. Remove the bolts that hold body (3) to the housing. Remove the body from the housing. 5. Remove idler gear (6) from the body.6. Remove O-ring seal (5) and the two lip type seals from the body. 7. Remove drive gear (7) and key (8) from the injection pump camshaft.Install Fuel Transfer Pump
1. Install the inner lip type seal in the body with tooling (A). The lip of the seal must be toward the pump gears.2. Install the outer lip type seal in the body with tooling (B). The lip of the seal must be toward the outside (away from the pump gears).
Always be extra careful not to scratch or cause damage to the machined surface of the pump body.
3. Install O-ring seal (2) in the body. Install idler gear (1) on the body. 4. Put the key for drive gear (3) in position in the injection pump camshaft and install the drive gear on the injection pump camshaft.
TYPICAL EXAMPLE5. Install tool (D) on the end of the shaft. 6. Put body (4) in position on the pump housing and install bolts (5). 7. Make a replacement of sleeve (6) with a new part and put it in position on the camshaft. Do not use the old part again. The pump camshaft puts new serrations (splines) in sleeve (6) when the sleeve is pushed on the camshaft. If an old part is used again, it can slip (slide around) on the camshaft after it is installed. If timing pin (7) was removed from the pump housing, install the timing pin again in the groove (slot) in the injection pump camshaft. The pin must be installed in the position shown so the injection pump camshaft will not turn during installation of the sleeve.8. Install the sleeve on the injection pump camshaft with tooling (C) until the sleeve makes contact with the end of the injection pump camshaft. 4N3371 Washer from tooling (C) is the same as the washer that holds the fuel injection pump drive gear to injection pump camshaft.
Do not hit the sleeve with a hammer to install it on the injection pump camshaft. This will put end force on the camshaft and will cause damage to the other components in the pump housing.
9. Pull the injection pump camshaft out of the pump housing as far as possible. Measure the clearance between the sleeve and the pump body. The clearance must be .023 .018 in. (0.58 0.46 mm).end by:a) install fuel injection pump housing and governor