20744939 Volvo.Penta Pump unit

START BY:a. remove fuel injection pump housing and governorb. remove governor
Be careful not to cause damage to the inlet and outlet ports on the bottom of the pump housing. The pump housing must be put on wood blocks before it is disassembled.
1. Remove bolts (3) from rear cover (2). Remove cover (2) and the gasket.2. Remove the shaft and gear from cover (2). Remove bushing (4) from the cover. 3. Remove bolts (10) that hold retainer (11) and gear (9) to the pump camshaft. Remove the retainer and gear.4. Remove the bolts and the cover from the pump housing.5. Remove idler gear (5). Remove pinion gear (8) from the pump housing with a soft hammer. Remove drive gear (6).6. Remove cover (7). 7. Remove bolts (14) from levers (17). Pull shaft (12) out of the pump housing. Remove levers (17), bushing (13) and spring (15).8. Remove bypass valve (16). Remove the O-ring seal, pin, piston and spring from the valve body. 9. Remove bushing (18) from each of the injection pumps with tool (A). Remove washers (19).10. Put identification marks on each injection pump as to its location in the pump housing. Hold the fuel racks in the center (zero) position, and carefully remove each injection pump with tool (B). 11. Remove the bolt that holds bracket (20) to the fuel injection pump housing. Remove bracket (20) and link (21). 12. Put identification marks on left rack (25) and right rack (24). Remove fuel racks (24) and (25).13. Remove spacer (23) and lifter (22) from the pump housing. Put identification marks on each of the spacers and lifters as to their location in the pump housing. 14. Remove camshaft (26) from the pump housing.15. Remove the upper and lower bearings that hold the pinion gear in the pump housing. 16. Remove the dowel and idler gear shaft from the pump housing with tool group (C). 17. Remove fuel rack bearings (27) from the fuel pump housing. 18. Remove the lip-type seals and bearings (29) from the pump housing with tooling (D).19. Remove the camshaft front and rear bearings (28) with tool group (E).Assemble Fuel Injection Pump Housing
1. Put fixture assembly (1) [part of tooling (A)] on the fuel pump housing with the dowels of the fixture in alignment with the left rack bore. Install the bolt that holds the fixture to the pump housing.2. Put a new bearing (2) in position between the fixture and the fuel rack bore with the tab of the bearing up. Put driver (3) [part of tooling (A)] in alignment with the bearing until the shoulder of the driver makes contact with the bottom of the fixture.3. Turn the fixture, and align the dowels in the fixture with the right rack bore. Install the bolt that holds the fixture to the pump housing.4. Do Step 2 for the left fuel rack bearing. 5. Install the camshaft front and rear bearings with tool group (B). Install the rear bearing until it is 4.8 0.5 mm (.19 .02 in.) from the rear surface of the pump housing. Install the front bearing until it is 1.0 0.5 mm (.04 .02 in.) from the front surface of the pump housing. Make sure both oil holes in the bearings are in alignment with the oil holes in the pump housing. 6. Install the lip-type seal in location (5) with tooling (C). Install the seal even with the outside surface and with the lip toward the outside.7. Install bearing (4) in the pump housing with tooling (D). Install the bearing until distance "X" is 38.23 0.51 mm (1.505 .020 in.). Dimension (X) is from the end of bearing (4) to the outer face of the pump housing base. 8. Install bearing (6) from the inside of the pump housing with tooling (E). The distance between bearings (6) and (4) must be 34.80 0.5 mm (1.370 .021 in.).9. Install the lip-type seal in location (7) even with the inner housing surface and with the lip of the seal away from bearing (6). 10. Install the lower bearing for the pinion gear with tooling (F). Install the bearing until it is even with the lower surface of the bearing bore.11. Install the upper bearing for the pinion gear with tooling (G). Install the bearing until it is even with the upper surface of the bearing bore. 12. Put clean engine oil on the camshaft and camshaft bearings. Install camshaft (8) as shown.
Pin (12) must not extend out from either side of the valve body.
13. Install spring (10) and piston (9) in valve body (11). Install pin (12). Install seal (13).14. Put clean engine oil on the O-ring seal and valve body. Install the oil bypass valve in the pump housing. 15. Install shaft (14) to a height of 16.8 0.5 mm (.66 .02 in.) and dowel (15) to a height of 6.4 0.5 mm (.25 .02 in.) above the surface of the pump housing.16. Install lifters (18) and spacers in their respective locations in the fuel pump housing. If new lifters and/or spacers are installed, make adjustment to the fuel pump timing dimension. See Fuel System Adjustments: Off Engine in Testing And Adjusting section.17. Install left fuel rack (16) and right fuel rack (17) on the dowel and in the fuel pump housing. 18. Install link (20) in the notches of the fuel racks.19. Install bracket (19). Bracket (19) can turn when the bolt is tightened. Do not let the bracket turn. 20. Install tool (K) in the injection pump housing to hold the fuel racks in the center (zero) position.21. Install the injection pumps, bushings (21) and felt washers with tool (H) and tool (J) as follows:a. Turn the crankshaft until the respective lobe is at its lowest point.b. Put the space