852565 Volvo.Penta Relay

start by:a) remove fuel injection lines 1. Put the fuel injection pump in correct timing with the engine as follows: a) Remove plug (1) from the governor plate. Turn the engine with tool (A) to put No. 1 piston at top center compression stroke.b) Install tool (B) in the opening in the governor plate to engage with the timing groove in the fuel injection pump camshaft. See FINDING TOP CENTER COMPRESSION POSITION FOR NO. 1 PISTON AND CAMSHAFT TIMING FOR THE FUEL INJECTION PUMP in TESTING AND ADJUSTING.2. Disconnect fuel lines (2) from the fuel transfer pump.3. Remove fuel line support bracket (3). 4. Disconnect fuel lines (4) from the governor plate. 5. Remove cotter pin and pin (8) that hold governor control cable (6).6. Loosen the nut that holds cable (6) to the engine bracket and remove the cable from the bracket.7. Disconnect air line (5) from the fuel ratio control.8. Disconnect fuel shutoff solenoid wires at connectors (7). 9. Remove vee belts (10) from the fan drive and belt tightener (11).10. Disconnect spring (9) from belt tightener (11).11. Remove the cover and gasket from the automatic timing advance housing.
Do not let retainer (12) drop in the housing.
12. Remove the four bolts and retainer (12) that hold the automatic timing advance to the fuel pump camshaft. 13. Remove bolts (14), washers, spacers and brackets (13) from each side of the fuel injection housing. 14. Install tooling (C) on the governor plate as shown. Fasten a hoist to tooling (C).15. Pull the fuel injection pump housing out of the timing gear housing.16. Remove the fuel injection pump housing and governor from the engine. Weight of the fuel injection pump housing and governor is 110 lb. (50 kg). 17. Inspect the two O-ring seals on the bottom and seal (15) on the front of the fuel injection housing. If needed, make a new replacement.Install Fuel Injection Pump Housing And Governor
Make sure there is no paint, dirt or foreign material on the machined surface of the fuel injection pump housing and the machined surface of the cylinder block. The surfaces must be clean before the fuel injection pump housing is installed.
1. Put 5P960 Multipurpose Type Grease on the two O-ring seals to hold them in place. Install the two seals on the bottom of the fuel injection housing over the inlet and outlet dowels. Install O-ring seal (1) on the front of the housing. Put a small amount of clean engine oil on the seal.2. Turn the fuel injection pump camshaft until tool (A) can be installed in the groove of the fuel injection pump camshaft.3. Install tooling (B) on the governor plate as shown.4. Fasten a hoist to tooling (B) on the fuel injection pump housing and governor. Put the unit in position on the engine. Make sure the fuel injection pump camshaft is in the automatic timing advance unit and the bolt holes in the fuel injection pump housing are in alignment with the holes in the engine. 5. Install the spacers, washers, bolts (3) and brackets (2) on each side of the fuel injection housing. 6. Connect fuel shutoff solenoid wires at connectors (7).7. Put governor control cable (6) in position on the engine bracket and tighten the nut that holds the cable to the bracket.8. Connect governor control cable (6) to lever (5) with pin (8) and the cotter pin.9. Connect air line (4) to the fuel ratio. 10. Connect fuel lines (9) to the governor plate. 11. Install fuel line support bracket (10).12. Connect fuel lines (11) to the fuel transfer pump.13. Install the retainer and the bolts that hold the automatic timing advance unit on the fuel injection pump camshaft. Tighten the bolts to a torque of 20 lb.ft. (27 N m) with the tool (A) (timing pin) in the fuel pump camshaft.14. Remove the timing pin and tighten the bolts to a torque of 100 5 lb.ft. (135 7 N m). 15. Install the gasket and cover (12) for the automatic timing advance. 16. Connect spring (13) to belt tightener (15).17. Install vee belts (14) on the fan drive and belt tightener (15).end by:a) install fuel injection lines