468983 Volvo.Penta Pressure pipe,cyl 3

2. Disconnect governor control linkage (1).3. Disconnect fuel lines at fuel filters.4. Remove line (2) to air fuel ratio control.5. Remove fuel filter and turbocharger mounting bracket (5).6. Remove fuel supply lines (4).7. Disconnect glow plug wire (8) (right side only).8. Remove six fuel injection line clamps (3).9. Remove fuel injection lines (7). Cap openings.10. Remove fuel injection pump oil return elbow (6).11. Remove pump mounting bolts, install 3/8"-16NC forged eyebolts, connect hoist, and remove pump and governor-weight 200 lbs. (113 kg).Install Fuel Injection Pump And Governor
1. Attach hoist and install pump and governor on engine.2. Connect fuel injection pump oil return elbow.3. Install fuel injection lines.4. Install fuel injection line clamps.5. Connect glow plug wire.6. Install fuel supply lines.7. Install fuel filter and turbocharger mounting bracket.8. Connect fuel lines at fuel filters.concluding step:a) install turbochargerDisassemble Fuel Injection Pump Housing
preparatory steps:a) remove fuel injection pump housing, and governor.b) remove governorc) remove variable timing unit 1. Remove the timing pin assembly from its storage position. Install one of the pin retaining bolts upside down through one of the flange holes. Install the pin assembly into timing hole and move rack back and forth slowly until the timing pin engages slot in rack. Depress timing pin until head of inverted bolt (1) touches housing.
Do not attempt to remove fuel injection pumps if rack is not positioned as outlined above.
2. Remove the fuel transfer pump (2).3. Identify each of the fuel injection pumps by its location in the fuel injection pump housing. Remove the pump mounting bolts. Pull straight up on each pump to remove it from housing. 4. Disassemble the fuel injection pumps as follows. Using wrench (A), remove the retainer. Remove the valve and spring. Pull the plunger out of the body to remove plunger, washer and spring.
Don't damage plunger surfaces. The body and plunger assemblies are not interchangeable.
5. Remove the cover (3). Remove the rack position indicator lever. Remove the timing pin assembly. 6. Remove the rack (4) from fuel injection pump housing. 7. Remove the lifter assemblies (5). Keep the lifter assemblies identified and together with their respective pumps.
Do not attempt to remove or replace the spacers in lifter assemblies (5). An improperly staked spacer can cause engine failure.
8. Remove the fuel transfer pump drive gear (6), mounting bolts and lock. 9. Remove the fuel injection pump housing bottom cover. Pull the fuel injection pump camshaft (7) out of the housing. 10. Using tool setup (B), remove the camshaft bearings. 11. Remove the rack bearings using tool setup (C).12. Remove the variable timing unit bearing from the fuel injection pump housing.Assemble Fuel Injection Pump Housing
1. Using tool setup (A), install the variable timing unit bearing with the hole in bearing aligned with hole in fuel injection pump housing.2. Install the three camshaft bearings using tool setup (C). 3. Install the two rack bearings using tool setup (B). The front rack bearing should be recessed .38 in. (9,65 mm) from the front face of housing. The rack rear bearing should be installed 6.372 in. (161,8 mm) from the variable timing unit end of fuel injection pump housing.4. Lubricate the camshaft with clean engine oil, and install it in housing. Install the fuel injection pump housing bottom cover. Install the fuel transfer pump drive gear, lock and mounting bolts. 5. Install the lifter assemblies (1) in their respective positions in housing. Lubricate the rack generously with clean fuel oil, and install it in housing. If new lifter assemblies and pumps are to be installed, it will be necessary to set the fuel pump timing dimension. See FUEL PUMP TIMING DIMENSION SETTING (OFF ENGINE) in TESTING AND ADJUSTING.6. Install one of the timing pin retaining bolts, upside down, through one of the flange holes in timing pin assembly. Insert the pin assembly into the timing hole in housing. Move the rack back and forth slowly until the timing pin engages slot in rack. Depress the timing pin until head of inverted bolt touches housing.
Do not attempt to install fuel injection pumps if rack is not positioned as outlined above.
7. Install rack position indicator lever (2) and cover. 8. Assemble the fuel injection pumps as follows. Lubricate all parts generously with clean fuel oil. Install the spring, washer and plunger in the body. Install the valve, spring and bonnet in body. Using wrench (D), tighten bonnet to 145 lb. ft. (20,05 0,7 mkg).9. Install the fuel injection pumps in their respective positions as follows: Rotate the camshaft until lifter assembly is down for the pump to be installed. Position the pump over the opening in housing. Sight down the pump and align the flat on gear with alignment pin in lifter assembly. Install the pump in housing. If the pump gear is properly aligned with alignment pin, the distance between pump body and fuel injection pump housing should be approximately 3/8 in. (10 mm) with the pump spring not compressed. Install the pump mounting bolts.10. Install the transfer pump adapter housing.11. Remove the timing pin assembly from timing hole in fuel injection pump housing. Install the pin assembly in its storage position in housing.concluding steps: a) install variable timing unitb) install governorc) install fuel injection pump housing and governor as a unit