3587204 Volvo.Penta Plug

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
B 230-6284 Timing Pin (Camshaft) 1
C 230-6283 Timing Pin (Crankshaft) 1
E 338-1054 Timing Tool
(Fuel Injection Pump) 1
F 1U-6396 O-ring Assembly Compound 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information.Refer to Systems Operation, Testing and Adjusting Manual, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Illustration 1 g01572496
Typical example
Note: A new fuel injection pump is supplied, locked in the correct position. Do not unlock the fuel injection pump before installation.
If the fuel injection pump timing has been lost, it is possible to reset the fuel injection pump timing. Follow Step 1.a through Step 1.e in order to reset the fuel injection pump timing.
Loosen locking screw (22) and slide spacer (21) to Position (AA). Tighten locking screw (22) to a torque of 9 N m (80 lb in). This will prevent the locking screw from tightening against the shaft of the fuel injection pump. The fuel injection pump is now unlocked.
Position Tooling (E) onto the shaft of fuel injection pump (1). Align the lever of Tooling (E) with Keyway (Y) and engage the lever into the keyway. Note: The lever of Tooling (E) should be a close fit in the keyway. If the lever is a loose fit in the keyway, it is not possible to reset the fuel injection pump timing.
Rotate the shaft of the fuel injection pump and engage the pin of Tooling (E) into Hole (Z). The fuel injection pump timing is now set in the correct position.
Loosen locking screw (22) and slide spacer (21) to Position (BB). Tighten locking screw (22) to a torque of 9 N m (80 lb in). The locking screw is now tightened against the shaft of the fuel injection pump. The fuel injection pump is now locked.
Remove Tooling (E).
Illustration 2 g01801934
Typical example
Inspect Bore (X) in front housing (20) for damage. If the bore is damaged, replace the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove" and Disassembly and Assembly, "Housing (Front) - Install".
Use Tooling (F) to lubricate a new O-ring seal (17). Install the O-ring seal onto fuel injection pump (1).
Align fuel injection pump (1) with front housing (20). Carefully install the fuel injection pump to the front housing. Note: The fuel injection pump should be supported by hand until the bolts are installed.
Install bolts (18) and new sealing washers (19). Tighten the bolts to a torque of 25 N m (18 lb ft).
If necessary, use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Centre Position for No.1 Piston".
Use Tooling (B) in order to lock the camshaft in the correct position. Use Tooling (C) in order to lock the crankshaft in the correct position. Refer to Disassembly and Assembly, "Gear Group (Front) - Remove and Install" for the correct procedure.
Install the fuel injection pump gear to the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump Gear - Install" and refer to Disassembly and Assembly, "Gear Group (Front) - Install". Note: Ensure that the fuel injection pump is unlocked after the installation of fuel injection pump gear is completed.
Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".
Illustration 3 g01566973
Typical example
Position support bracket (14) and install bolts (15) finger tight. Install bolt (16) finger tight.
Tighten bolt (16) to a torque of 44 N m (32.5 lb ft). Tighten bolts (15) to a torque of 22 N m (16 lb ft).
Illustration 4 g01563276
Typical example
Illustration 5 g01563275
Typical example
Install the banjo bolt and new sealing washers to tube assembly (8). Install tube assembly (8) for the oil feed to the fuel injection pump. Tighten the banjo bolt and the nut to a torque of 15 N m (11 lb ft).
Install a new fuel injection line (5). Refer to Disassembly and Assembly, "Fuel Injection