874243 Volvo.Penta Relay

With Turbocharger
Without Turbocharger1. Disconnect two fuel lines (1). Cap or plug immediately.2. Remove four bolts (5). When installing, tighten the four bolts gradually and evenly to a torque of 22 N m (16 lb. ft.).3. Remove two lock plates (3).4. Remove fuel pump (2) and gasket (4) (not shown). Replace gasket when installing the fuel pump. If the fuel pump is difficult to remove, rotate the crankshaft until the camshaft eccentric, which operates the fuel pump lever, is in a position which will free the rocker lever of the fuel pump. When installing, make sure the camshaft eccentric is in the minimum lift position before the fuel pump is installed. Clean the face of the fuel pump and the cylinder block before installing fuel pump. For the installation of the fuel pump, reverse the removal steps.5. After installation of the fuel pump is complete, loosen the vent screw on the fuel filter head and operate the priming lever on the fuel pump to remove air from the fuel system between the fuel pump and the fuel filter. Operate the priming lever until fuel, free of air, comes from the vent screw. Tighten the vent screw on the fuel filter.6. Start the engine and check for either fuel or air leaks from the fuel pump.Disassemble & Assemble Fuel Pump
Start By:a. remove fuel pump 1. Mark or identify the halves of the fuel pump for later assembly.2. Remove the screw that holds cover (1).3. Remove gauze (2).4. Remove the screws that hold the halves of the fuel pump together.5. Turn the diaphragm assembly (5) 90° to release the pull rod from link arm (8). Remove the diaphragm assembly.6. Remove stern seal (6), spring seat washer (7) and spring (12) from the pull rod. The diaphragm and pull rod assembly are not serviced and have to be replaced as a unit.7. Valves (4) are peened in and can be removed with a suitable lever. Some of the peened metal will have to be removed before the valves can be removed.8. To remove the link arm, hold rocker lever (11) in a vise and hit the body of the fuel pump with a soft hammer to release retainers (10).
Be careful not to damage the face of the pump body.
9. Remove the rocker lever, pin (9), the link arm and the return spring. Before beginning assembly, check all components for wear or damage. Replace if necessary. The following steps are for the assembly of the fuel pump.10. Clean all components before beginning assembly.11. Install seat washers (3).12. Push valves (4) into position.
The valves are the same, but can be installed incorrectly. One valve is installed in reverse of the other. Refer to the illustration C56482P1 for correct assembly.
13. When the valves are installed correctly, peen the edge of the valve housing in six places, evenly divided, to keep the valves in position.14. Install rocker lever (11), pin (9) and link arm assembly (8) into the bottom half of the fuel pump.15. Install the return spring, make sure the ends of the spring are installed correctly.16. With a light hammer and a suitable adaptor, install two retainers (10) in their grooves in their casing until they fasten the pin. Peen the open ends of the grooves to fasten the retainers in position.17. Install the diaphragm spring into its location under the diaphragm. Put the spring seat washer and a stem seal into position on the pull rod.
Make sure that the small diameter at the top of the seal is on the round section of the pull rod.
18. Put the diaphragm assembly in position over the lower half of the body with the blade of the pull rod aligned with the slot in the link arm.19. Press lightly down on the diaphragm until the notch in the pull rod is in the slot in the link arm and turn the diaphragm 90° in either direction. This action will engage and retain the pull rod in the slot of the link arm.20. Push the lever arm towards the pump body until the diaphragm is level with the body flange. Install the top half of the body in position with the marks on the flanges in alignment. Keep pressure on the rocker lever. Install the spring washers and the screws. Tighten the screws evenly.21. Install the gauze filter. Install the cover.
Make sure the rubber seal is installed correctly.
22. Install the screw. Refer to Systems Operation, Testing & Adjusting for the 3054 & 3056 Diesel Engines, Module No. SENR5542 for the topic, "Fuel Lift Pump Pressure Test".End By:a. install fuel pump