3825397 Volvo.Penta Roller

start by: a) separation of governor from fuel injection pump housing 1. Remove the cover (1) for the rack centering pin. Move the rack until the centering pin can be pushed down. Install the cover so the edge of the cover holds the pin down.2. Remove the protection cap and felt washer (2).3. Install wrench (A) and remove bushing (3).4. Remove seal (4). 5. Install extractor (B). Hold the rack toward the driven end of the pump housing and remove the fuel injection pump.
Do not remove fuel injection pumps without the rack centering pin installed and the rack held toward the driven end of the pump housing.
6. Remove spacer (10). Put identification on spacers (10), fuel injection pumps, and lifters (14) as to their respective location in the pump housing. These parts must be installed back in their original positions in the pump housing.7. Disassemble injection pumps using the following method: a) Remove bonnet (5), ring (8), spring (7), and check valve (6) from barrel (9).b) Remove plunger assembly (11), washer (12), and spring (13) from barrel (9).
During disassembly and assembly of fuel injection pumps, use much care to prevent damage to the surfaces of plunger assemblies. The barrel and plunger assemblies have a special fit with each other, and are not to be used with other barrels or plunger assemblies.
8. Remove the cover for the rack centering pin. Remove the spring and pin.9. Remove the rack from the pump housing. 10. Remove lifters (14). Put identification on lifters so they can be installed back into their original positions in housing. 11. Remove the bolt, lock and plate (17).12. Remove spring (15) and gear assembly (18) from the camshaft. 13. Remove the camshaft (19) from the pump housing. 14. Install tool group (C) and remove the camshaft bearings from the pump housing.15. Remove the two rack bearings (16) from the pump housing.Assemble Fuel Injection Pump Housing
1. Install camshaft bearings in pump housing with tool group (C). Install the bearing at governor end of pump housing so the oil hole in bearing is in alignment with oil hole in pump housing. Install the two bearings on each end of housing so the edge of bearing will be even with end of pump housing. 2. Install the two rack bearings in pump housing with tooling (D). Install the bearing at governor end of pump housing so it is .195 .005 in. (4.95 0.13 mm) inside end of housing. Install rack bearing at other end of housing so it is even with face of pump housing.3. Put clean oil on the camshaft and install it in the pump housing. 4. Put the governor drive gear (1) and spring (2) in place on camshaft. Install the camshaft plate (3), bolt and lock. 5. Install the lifters in their respective positions in pump housing. Put clean oil all over the rack (4) and install it in the pump housing. The (slot) groove in rack must be toward governor end of pump housing.6. Install the spring, rack centering pin and cover. Push the pin down and put the edge of the cover over end of pin to hold the pin down.7. Install the spacers in their respective positions in housing. If new lifters and pumps are to be installed, an adjustment must be made to the fuel pump timing dimension. See FUEL INJECTION PUMP TIMING DIMENSION SETTINGS OFF ENGINE in TESTING AND ADJUSTING SECTION. 8. Install the dial indicator, from tool group (E) on pump housing as shown. Hold rack toward driven end of pump housing, and move dial indicator to the zero position.9. Assemble the injection pumps using the following method: a) Put clean fuel oil on all parts of the fuel injection pumps. b) Install the spring (7), washer (5) and plunger assembly (6) into the barrel (8).c) Install the spring (12), check valve (9), bonnet (11) and ring (10) on the barrel (8).
Do not install fuel injection pumps in pump housing until rack has been moved to center position. Rack is in center position when centering pin is held down and rack held toward driven end of pump housing.
10. With the rack in center position, install the fuel injection pumps as follows: a) Turn camshaft until lobe of camshaft is down for pump being installed. b) Install extractor (B) on the pump.c) Look down pump and put notches (13) in bonnet and barrel in alignment with (slot) groove (14) in pump gear. The slot (14) should be in alignment with center of notches (13). Put pump in pump housing with notches (13) in alignment with guide pins in bore of pump housing. Install pump in its respective position in pump housing. d) Install the seal and bushing (15). Push down on extractor (B), and tighten the bushing by hand (finger tight only) until bushing is even with top surface of housing. If bushing can not be installed this far by hand, remove it. Remove pump. Put parts in alignment and install pump again.
Do not tighten bushing even with face of housing by using a wrench. If pump has been installed correctly, the bushing can be tightened with the fingers until even with face of housing.
e) Install wrench (A) and tighten bushing to torque of 50 10 lb.ft. (6.9 1.4 mkg). f) After each pump is installed, check the rack travel as follows. Move cover (16) off centering pin and let pin come up. Move the rack in both directions and take a reading on the dial indicator. If pump is installed correctly, total rack travel will be about .800 in. (20.3 mm). If pump has been installed one tooth off total rack travel will be decreased to about .600 in. (15.2 mm). If total rack travel can not be made, remove the pump. Put components in alignment and install pump again. g) Install wrench (A) and tighten bushing to a torque of 150 10 lb.ft. (20.7 1.4 mkg). Install felt washers and protection caps.h) Do