1577376 Volvo.Penta Relay

1. Disconnect fuel lines (1) and (3) from fuel transfer pump (2). 2. Remove bolts (4) that hold fuel transfer pump (2) to the injection pump rear plate.3. Remove the fuel transfer pump and gasket.Install Fuel Transfer Pump
1. Make a replacement of the O-ring seal on the fuel transfer pump if needed. 2. Put the gasket and fuel transfer pump (1) in position on the rear plate.3. Turn the fuel transfer pump to engage the gears.4. Install the bolts that hold the fuel transfer pump. 5. Connect fuel lines (2) and (3) to the fuel transfer pump.Disassemble Fuel Transfer Pump
start by:a) remove fuel transfer pump 1. Remove tachometer drive (2) from transfer pump cover (1). 2. Remove bolts (4). Make a separation of cover (1) from pump body (3). 3. Remove the lip type seal (5) from the cover.4. Remove plug (7), seal, spring (8) and plunger (bypass valve) (6) from the cover. 5. Remove idler gear (12) from the pump body.6. Remove nut (11), gear (9) and key (14) from shaft assembly (10).7. Remove O-ring seal (13) and shaft assembly (10) from the pump body. 8. Remove check valve (15).9. Remove bushing (16), two lip type seals and the bottom bearing from pump body (3).Assemble Fuel Transfer Pump
1. Install bearing (2) a distance of .03 .02 in. (0.76 0.51 mm) below the gear surface of pump body (3) with tooling (A).2. Install check valve (1). Move the metal (stake) in three locations (4) with even spaces in between to hold check valve (1) in place. 3. Install lip type seal (6) with tooling (A). Install seal (6) until it is .97 .02 in. (24.6 0.5 mm) from the bottom surface of body (3) and with the lip of the seal toward bearing (2) as shown.4. Install lip type seal (5) with tooling (A). Install seal (5) until it is .56 .02 in. (14.2 0.5 mm) from the bottom surface of body (3) and with the lip of the seal away from bearing (2) as shown.5. Install bearing (7) even with the surface on the drive gear end of pump body (3) with tooling (A).6. Put a small amount of clean engine oil on O-ring seal (8) and install the seal on the pump body. 7. Put the seal guide, part of tool group (B), in position on shaft assembly (9) as shown. Put clean diesel fuel on the seal guide and on the lips of seals (5) and (6). Put shaft assembly (9) in position in the pump body. 8. Install the key, gear (10) and nut (11) on shaft assembly (9). Tighten nut (11) to a torque of 22 5 lb.ft. (28 7 N m).9. Install idler gear (12) in pump body (3). 10. Put a small amount of Permatex No. 2 on the outside diameter of seal (13). Install lip type seal (13) with tooling (A). Install seal (13) until it is .75 .02 in. (19.1 0.5 mm) from the top surface of cover (14) with the lip toward the inside as shown. Put a small amount of clean diesel fuel on the lip of the seal. 11. Install bypass valve (15), spring (17), seal and plug (16) in cover (14). Tighten plug (16) to a torque of 27 3 lb.ft. (38 4 N m).
Do not get liquid gasket material into pump.
12. Put 7M7260 Liquid Gasket Material on the pump body surface that makes contact with cover (14). Install cover (14) on pump body (3). Shaft assembly must turn by hand after cover (14) is installed.13. Install tachometer drive (18) on cover (14).end by:a) install fuel transfer pump