20460486 Volvo.Penta Repair kit

start by:a) remove fuel injection linesb) remove starter 1. Remove the nuts that hold cover (1) to the timing gear cover. 2. Loosen bolt that holds fuel injection drive gear to the fuel injection pump camshaft until the washer is approximately 1/8 in. (3.2 mm) away from the drive gear. Do not remove the bolt at this time. Install tooling (A) on the drive gear. Tighten the screw in tooling (A) until the drive gear is loose. Remove tooling (A), the bolt and washer. The drive gear will stay in the timing gear cover. If the fuel injection pump drive gear does not loosen from the camshaft, turn the bolt and washer out 1/8 in. (3.2 mm) away from the drive gear. Install tooling (A) on the gear and loosen the gear from the camshaft.3. Disconnect fuel supply line (2) and fuel return line (3). Disconnect bleed line (4). Disconnect fuel pressure line (8).4. Disconnect the drain line under the fuel pump.5. Remove the bolt that holds clip (5).6. Disconnect governor linkage (6) from the governor. Remove the two bolts that hold bracket (7) in place. 7. Disconnect cable (9) from the governor. Remove the bolt that holds the clip for the cable to the head.8. Remove the bolts that hold adapter (10) in place. Remove the adapter. Loosen the bracket from the governor and pump housing to the adapter if necessary to remove the adapter. 9. Remove nuts (12) that hold the fuel injection pump housing and governor to the timing gear plate and remove fuel injection pump housing and governor (11).Install Fuel Injection Pump Housing And Governor
1. Put the No. 1 piston at the top center compression position before the fuel injection pump housing and governor are installed on the engine with the following procedure: a) install tool (A) in place of starter. Remove plug (1) from the flywheel housing.b) With tool (A) turn the crankshaft clockwise (as seen from the front of the engine) until a 3/8"-16 NC bolt 21/2 in. long can be installed through the timing hole in the flywheel housing and into the hole in the flywheel. Never turn the crankshaft backward to install the bolt in the flywheel. c) Disconnect glow plug wires (2) and remove valve cover (3) from the engine.d) Check to see if both rocker arms 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.e) If both rocker arms can not 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 th engine) one full turn (360°) and install the bolt again. 2. Remove timing pin (4) from storage hole (5). Remove the bolt from the cover and install the timing pin in the groove (slot) in the fuel injection pump camshaft. 3. Inspect the O-ring seal for the fuel transfer pump. Install a new seal if needed. Put clean engine oil on seal. Put the fuel injection pump housing and governor in position on the engine. Install the nuts that hold it in place. Connect drain line to fuel pump.4. Install the washer and bolt that hold the pump drive gear to the camshaft. Tighten the bolt finger tight only. 5. Put a force of approximately 50 lb.ft. (67.8 N m) on the drive gear with tool (B). Tighten the bolt to a torque of 110 5 lb.ft. (149 7 N m).6. Check the timing to make sure it is correct: a) Remove the timing pin from the pump camshaft and the bolt from the flywheel.b) Turn the crankshaft clockwise (as seen from the front of the engine) approximately 1/2turn. Install the timing pin again.c) While the crankshaft is turned clockwise (as seen from the front of the engine), push on the timing pin until it slides into the groove (slot) in the pump camshaft.d) Install the bolt in the flywheel. The timing is correct when the bolt is installed in the flywheel and the timing pin is installed in the groove (slot) in the pump camshaft.e) Remove the timing pin and the bolt. Install the plug in the flywheel housing. Install the bolt in the cover on the pump housing. 7. Install cover (6). Install the nuts and washers that hold the cover in place. Tighten the nuts to a torque of 20 5 lb.ft. (25 7 N m).8. Install the valve cover. See VALVE COVER.9. Remove tool (A) from the flywheel housing. 10. Install adapter (9). Tighten the bracket from the governor and pump housing if it was necessary to remove the adapter.11. Connect cable (7) to the governor. Install the bolt that holds clip (8) in place.12. Install the two bolts that hold bracket (7) in place. 13. Connect fuel pressure line (13), bleed line (12), fuel return line (11) and fuel supply line (10) to the fuel pump.14. Connect governor linkage (14) to the governor. Install the two bolts that hold bracket (15) in place.end by:a) install starterb) install fuel injection linesc) adjustment of high and low idle (See GOVERNOR ADJUSTMENTS in TESTING AND ADJUSTING)Separation Of Governor From Fuel Injection Pump Housing
start by:a) remove fuel injection pump housing and governor1. Put the fuel injection pump housing and governor in position on tool (A).2. Remove the bolts that hold the governor housing to the fuel injection pump housing. 3. Remove governor housing (2) from the fuel injection pump housing.4. Remove cover (1) over the stop bar. 5. Remove spring (5), (wave) washer (4) and guide (3) from the governor housing. 6. Remove the nut and bolt that holds stop bar (6) to the fuel injection pump housing. Remove the stop bar. 7. Remove seat (7) and over fueling spring (8). 8. Push