949246 Volvo.Penta Plug

1. Remove the nut and bolt (2) to disconnect linkage (1) from the governor control shaft. 2. Remove plug (3) from the fuel injection pump housing. 3. Install tool (A) in the fuel injection pump housing as shown. Move governor control lever (4) to the fuel "ON" position until the right rack stops against tool (A). The racks are now in the center (zero) position. The racks must be in the center (zero) position before the fuel injection pumps can be removed. 4. Disconnect fuel injection lines (5), as needed from the fuel injection pumps. Put caps or plugs on all fuel system openings. 5. Remove washer (6) from the fuel injection pump. 6. Use tool (B) to remove bushing (7) from the fuel injection pump housing. 7. Remove O-ring seal (8) from the fuel injection pump. 8. Use tool (C) to remove fuel injection pump (9) from the fuel injection pump housing.
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.
9. Remove spacer (10). The following steps are for the installation of the fuel injection pumps. Before the fuel injection pumps can be installed, the racks must be in the center (zero) position.10. Put spacer (10) in position in the fuel injection pump housing bore. Make sure the correct spacer is with each pump. 11. Use tool (C) to install fuel injection pump (9). Make sure the fuel injection pump is installed straight down into the housing bore so the space in the gear segment of the pump is in alignment with dowel (11) and the groove in barrel engaged with dowel (11) in the pump housing.12. Install O-ring seal (8) on the pump.13. Install bushing (7) in the fuel injection pump housing with tool (B). If the fuel injection pump is in the correct position, the bushing can be installed with fingers until it is even with the pump housing. Tighten the bushing to a torque of 205 14 N m (150 10 lb.ft.).14. Install washer (6) on the fuel injection pump.15. Connect fuel lines (5) to the fuel injection pumps. Use tool (D) to tighten the nuts to a torque of 40 7 N m (30 5 lb.ft.).16. Remove tool (A) from the fuel injection pump housing. Install the plug.17. Connect control linkage (1) to the governor control shaft with bolt (2) and the nut.18. Check the correct installation of the fuel injection pumps. See Installation Of Injection Pump in Systems Operation Testing And Adjusting.
If one or more of the injection pumps have been installed wrong, damage to the engine is possible if caution is not taken when the engine is first started. Make preparation to close off the air intake to stop the engine if necessary.
Disassemble And Assemble Fuel Injection Pumps
Start By: a. remove fuel injection pumps
Be careful when the injection pumps are disassembled. Do not cause damage to the surface on the plunger. 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.
1. Remove ring (7). Make a separation of bonnet (1) from plunger and barrel assembly.2. Remove valve (3), collar (8) and spring (2) from the bonnet.3. Remove plunger (6), washer (5) and spring (9) from barrel (4).4. Put plunger (6), washer (5) and spring (9) in position on barrel (4). Put check valve assembly (3), spring (2) and collar (8) in position in bonnet (1). Connect bonnet (1) and barrel (4) together with ring (7).5. Put the space in gear segment (10) in alignment with the groove in barrel (4).End By: a. install fuel injection pumps