940312 Volvo.Penta Plug

*Part of 6V-4096 Governor Adjusting Tool.Start By:a. remove fuel injection linesb. disassemble governor ****Disassemble the governor far enough so Tool (E) of "Install Fuel Injection Pumps" can be installed. 1. Remove plug (1) from the rack zero pin hole. Remove two bolts (2) and cover (3). 2. Move the rack toward the rear of the engine until Tool (A) can be installed to hold the rack in the "zero" position. Install Tool (A) in the rack zero pin hole. 3. Use Tool (B) and a suitable wrench to loosen bushing (4). After bushing (4) has been loosened, remove Tool (B). 4. Install Tool (C) and compress the fuel pump spring. Hold Tool (C) in position and remove bushing (4). 5. Check seal (5) on bushing (4) for damage or wear and replace with a new part if necessary. 6. Remove fuel injection pump (6) with Tool (D).
When injection pumps, spacers and lifters are removed from the injection pump housing, keep the parts of each pump together so they can be installed back in their original location.
7. Remove spacers (7) from the pump housing.Install Fuel Injection Pumps 1251-012
*Part of 6V-4096 Governor Adjusting Tool Group**Part of 6V-9128 Rack Position Tool Group 1. Move the rack until Tool (A) can be installed to hold the rack in the zero position. The rack must be in the zero position to install the fuel injection pumps. Spacers (2) are the same thickness for each fuel injection pump so they can be mixed. The fuel injection pump plungers and barrels are sets and cannot be mixed.2. Install spacers (2) in the fuel pump housing.3. Install Tool (B) on the bonnet of the fuel pump as shown.4. Install the fuel pump in the pump housing with the saw cut slot (5) in the gear in alignment with small pin (1) in the lifter assembly and groove (4) in the barrel in alignment with large pin (3) in the pump housing. 5. Install the seal and bushing (6) on the fuel pump. 6. Put Tool (C) in position on the fuel pump housing as shown.7. Lower the handle slowly and carefully. If the fuel pump is not installed correctly, the handle will not go all the way down. Do nottry to use force on it. Remove and install the tooling and the fuel pump again. 8. Make sure the seal is in its correct position, and start to tighten bushing (6) with Tool (D). Tighten the bushing to a torque of 260 15 N m (190 10 lb ft).Back off 180 degreesand tighten the bushing again to a torque of 260 15 N m (190 10 lb ft). 9. After each fuel pump has been installed, follow the steps below to check total rack travel to make sure each pump has been installed correctly.a. Install Tool (E) on the fuel pump housing as shown and zero the dial indicator.b. Remove Tool (A) from the fuel pump housing.c. Move rack (7) in and out of the fuel pump housing to measure rack travel. Rack travel is approximately 9.62 mm (.379 in)in the plus "Full Fuel" direction and 10.40 mm (.410 in)in the minus "Shutoff" direction. If this measurement is not obtained, center the rack, install Tool (A), and remove and install the fuel pump again. One tooth off and rack travel is approximately 6.35 to 6.82 mm (.250 to .269 in)in the plus direction and 7.02 to 7.05 mm (.276 to .278 in) in the minus direction. 10. Install plug (8), cover (9), and two bolts (10).End By:a. assemble governorb. install fuel injection linesDisassemble & Assemble Fuel Injection Pumps 1251-017
*See SMHS8378 for the correct tool usage.Start By:a. remove fuel injection pumps
Be careful when the injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
Do not remove the gear from the plunger. The gear and plunger are assembled and adjusted at the factory.1. Pull plunger (4) and washer (3) out of barrel (1) and spring (2).2. Remove spring (2) from barrel (1). 3. Use the following procedure to put the fuel pump in position on Tool (A):a. Select the correct turret position.b. Place a barrel assembly into the turret.c. Loosen the nut on the clamp.d. Adjust clamp end (6) until the bonnet is almost touching the barrel when the clamp handle is in the locked position.e. Tighten the nut on the clamp.4. Use Tool (B) to expand ring (5), and carefully lift it off the fuel pump.5. Slowly release the clamp handle of Tool (A), and remove the lockring.6. Remove bonnet (7), spring (8) and valve (9) from barrel (1). The following steps are for assembly of the fuel injection pumps.
Put clean fuel on all parts during assembly.
7. Put spring (8) and valve (9) in bonnet (7).8. Put bonnet (7), barrel (1) and ring (5) in position on Tool (A).9. Put the barrel assembly in position on Tool (A). Lower the handle on Tool group (A) to hold the fuel pump together.10. Use Tool (B), and lower ring (5) on to the barrel and the bonnet to hold them together.11. Remove the barrel assembly from Tool (B).12. Install spring (2) on barrel (1).13. Install washer (3) on plunger (4). Make sure the spring seat on the washer is away from the gear on the plunger.14. Install plunger (4) in barrel (1). Make sure spring (2) is engage in the spring seat on washer (3).End By:a. install fuel injection pumps