3825078 Volvo.Penta Radiator stay, left

1. Remove the cotter pin from the pin holding rod (1) to the governor control lever. Disconnect rod (1) from the governor control lever.2. Remove the bolt holding rod (2) to the governor control lever.3. Remove oil lines (3) and (4).
Cap or plug all fuel system openings to keep dirt and other foreign material out of the fuel system.
4. Disconnect four fuel injection lines (5) at both ends. Remove fuel injection lines (5) from the engine. Refer to the topic "Remove & Install Fuel Injection Lines" in this module for further information.5. Disconnect fuel line (9) from the fuel injection pump.6. Disconnect fuel line (8) from the fuel transfer pump.7. Loosen bolt (7) and nut (6). Move the alternator toward the engine. Remove the V-belt from the alternator pulley.
Typical Example8. Remove the plug from the front of the timing gear cover to gain access to the fuel pump drive gear and bolt (10).9. Loosen bolt (10) a maximum of one full turn.10. Remove three bolts (11).11. Loosen three nuts (12) that hold the fuel injection pump housing to the timing gear plate. Loosen the nuts until they are even with the end of the studs.
Typical Example12. Loosen the drive gear from the fuel injection pump camshaft with tooling (A) as follows:a. Install tooling (A) in the position shown.b. Tighten the forcing screw in tool (A) until the drive gear is loosened from the fuel injection pump drive shaft.c. Remove tooling (A) from the timing gear cover. Remove the bolt and washer from the fuel injection pump camshaft.13. Remove three nuts (12). Remove the fuel injection pump housing and governor from the engine. The weight of the fuel injection pump housing and governor is 22 kg (49 lb).14. Remove the O-ring seals from the fuel injection housing.Install Fuel Injection Pump Housing & Governor
1. Install the fuel injection pump housing and governor on tooling (A), or use a suitable vise to hold it.2. Remove the bolts and cover over the timing pin hole in the pump housing.3. Install the washer and bolt (1) that is used to hold the drive gear to the fuel injection pump camshaft.4. Install tool (B) in the hole of the fuel injection pump housing. Use bolt (1), and turn the fuel injection pump camshaft until tool (B) engages in the notch in the camshaft.5. Remove the bolt and washer from the camshaft.6. Remove the fuel injection pump housing and governor from tooling (A). 7. Install O-ring seals (2) and (3) in the fuel injection pump housing. Put clean engine oil on the O-ring seals.
Typical Example8. Put the fuel injection pump housing and governor in position on the engine, and install three nuts (4).9. Put clean oil on the threads of bolt (1). Install the bolt and washer to hold the drive gear to the fuel injection pump camshaft. Tighten the bolt finger tight only. Bolt (1) must be tight enough to hold the gear clearance (backlash) out of the timing gears when the engine is turned. However, the timing gear must be able to turn on the shaft when the engine is turned to put the No. 1 piston on the top center compression position (TDC).
Typical Example10. Put No. 1 piston at the top center compression position (TDC) with the following procedure:a. Remove plug (5) from the flywheel housing.b. Turn the crankshaft clockwise (as seen from the front of the engine) until a 3/8" -16 x 2 in. (50.8 mm) bolt can be installed through the timing hole in the flywheel housing and into the hole in the flywheel. c. Remove the valve cover from the valve cover base. Check to see if both rocker arms (6) for the No. 1 piston can be moved backward and forward by hand. The No. 1 piston is at the top center compression position when the bolt is installed in the flywheel, and both rocker arms for No. 1 piston can be moved backward and forward. If both rocker arms cannot be moved, the No. 1 piston is not at the top center compression position. Remove the bolt from the flywheel. Turn the crankshaft clockwise (as seen from the front of the engine) one full turn (360°), and install the bolt again.11. With the timing pin in the notch of the fuel injection pump camshaft and the timing bolt in the flywheel, tighten the bolt which holds the drive gear to the fuel injection pump camshaft to a torque of 175 7 N m (129 5 lb.ft.).12. Check the timing as follows:a. Remove both the timing pin and timing bolt.b. Turn the crankshaft clockwise (as seen from the front of the engine) two full turns, and install the timing pin and bolt again.c. The timing is correct if both the timing pin and timing bolt can be installed at the same time. The timing procedure must be done again if the timing pin and timing bolt cannot be installed at the same time.d. Remove the timing pin and timing bolt when the timing is correct.13. Install the plug in the flywheel housing.14. Install the valve cover.
Typical Example15. Install three bolts (7) to secure the fuel injection pump to the support.16. Put the gasket and cover (8) in position on the fuel injection pump housing, and install the bolts that hold them in place.17. Install plug (12) in the timing gear cover.18. Put V-belt (11) in position on the alternator pulley. Adjust the belt tension, and tighten bolts (9) and (10).19. Use a belt tension gauge, such as a Borroughs Tool Company part No. BT-33-95, to check the belt tension. The gauge reading should be 534 22 N (120 5 lb.) for a new belt and 400 44 N (90 10 lb.) for a used belt.20. Install guard assembly (13) on the radiator. 21. Install rods (15) and (16).22. Install four fuel injection lines (17) onto the engine. Refer to the topic "Remove & Install Fuel Injection Lines" in this module for