20459641 Volvo.Penta Plug

Start By:a. remove fuel injection linesb. remove valve cover Fluid Spillage ContainmentCare must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Products Guide", NENG2500 for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove six nuts (1) and the washers and remove cover (2). 2. Remove center bolt (3) and spacer (4). 3. Install center bolt (3), leaving a 6.35 mm (.250 in) gap. Install Tooling (A) as shown. Tighten the stud to pull the fuel pump drive gear loose from the taper on the fuel injection pump camshaft.4. Remove Tool (A) and bolt (3). 5. Remove tube assemblies (6) and (10). Disconnect one end of tube assemblies (8) and (9). Disconnect clamp (11). Remove two bolts (7) and the washers and remove filter base (5) with filter and gasket. 6. Remove two bolts (12) and the washers and gasket. Remove two bolts (13) and the gasket. Remove tube assembly (14). 7. Use a lifting sling and a hoist to secure the fuel injection pump housing and governor.8. Disconnect solenoid ground wire (16). Remove three nuts (17). Remove two bolts (18) and the washers and remove the fuel injection pump housing and governor from the engine. The weight of the fuel injection pump housing and governor is approximately 32 Kg (70 lb).9. Remove the O-ring seals from the fuel injection pump housing and governor.Install Fuel Injection Pump Housing & Governor
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
Number 1 piston must be set at top center (TC) to perform all timing procedures.
The engine is seen from the flywheel end when the direction of crankshaft rotation is given. 1. Remove the electric starting motor.2. Install Tool (A) on flywheel housing as shown.3. To find top center (TC) for No. 1 piston;a. Turn the flywheel clockwise (opposite the direction of engine rotation) approximately 30 degrees. This removes all play from the timing gears. If you go past the bolt hole, you must repeat Step (3a). b. Remove plugs (19) and (20). c. Turn the flywheel counterclockwise until a 3/81/2 -16 NC × 3 bolt (22) can be installed in the flywheel through the hole in the flywheel housing. The No. 1 and No. 6 pistons are now at top center position. Plug (20) was removed for viewing through inspection hole (21).d. Remove the valve cover. See the topic "Remove & Install Valve Cover" in this module. The No. 1 piston is on the compression stroke when the valves of the No. 1 cylinder are closed. The rocker must be free to move up and down.4. If No. 1 piston is not on the compression stroke, remove the 3/81/2 -16 NC × 3 bolt (22) and turn the flywheel 360 degrees counterclockwise. Install bolt (22) as before. The No. 1 piston is now at top center (TC).
Typical Example5. Install Tool (C) in the fuel injection pump housing as shown. Push on Tool (C) and turn injection pump camshaft (27). When Tool (C) engages the groove (slot) in the camshaft, the fuel injection pump is in the No. 1 piston TC position.6. Be sure O-ring seals (23), (24), (25) and (26) are in position on the fuel injection pump housing and governor. Put clean engine oil on the seals. 7. Attach a hoist and put the fuel injection pump housing and governor in position on the timing gear plate and oil manifold. Install three nuts (17) and two bolts (18) and the washers. Connect solenoid ground wire (16). Make sure Tool (C) remains in place. 8. Install washer (4) with the large side out. Install bolt (3) finger tight. Be sure that Tool (C) is in the notch in the camshaft of the fuel injection pump. 9. Install Tool (B) on the fuel pump drive gear. With timing bolt (22) in position in the flywheel, and Tool (C) in position in the fuel system, apply 68 N m (50 lb ft) force to the fuel pump drive gear in a clockwise direction, (as viewed from the front of the engine) with Tool (B) and a suitable torque wrench. While holding the 68 N m (50 lb ft) force on Tool (B), torque the drive gear bolt to a torque of 270 25 N m (200 18 lb ft). Remove Tools (B) and (C) from the fuel pump and remove bolt (22) from the flywheel.10. Use Tool (A) and turn the engine flywheel two complete revolutions. When bolt (22) goes in the hole in the flywheel and Tool (C), is installed in the notch in the camshaft, the timing is correct.11. Install plugs (19) and (20).12. Remove Tool (A). Install the starter. 13. Put cover (28) and the gasket in position. Install four bolts (29).14. Put the fuel filter base, the gasket, and fuel filter (30) in position. Install two bolts (31) and the washers.15. Install tube assemblies (6) and (10). Connect wire (16). Connect (8) and (9). 16. Put cover (2) in position. Install nuts (1) and six washers. Tighten nuts (1) to a torque of 27 7 N m (20 5 lb ft).End By:a. install valve coverb. install fuel injection lines