242119 Volvo.Penta Screw

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
B 136-4632 Timing Pin (Crankshaft) 1
268-1966 Adapter 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tooling is used in the aperture for the electric starting motor.Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High-Pressure Fuel Lines" for safety information.Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Ensure that wiring harness are correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.
Illustration 1 g06132053
If necessary, follow Step 1.a through Step 1.d to install bracket (31) to fuel injection pump (19).
Position fuel injection pump (19) in a suitable stand.
Position bracket (31) onto fuel injection pump (19). Ensure that the bracket is correctly orientated.
Install bolts (30) hand tight.
Tighten bolts (30) to a torque of 22 N m (195 lb in).
If necessary, install flow control valve (12). Refer to Disassembly and Assembly, "Flow Control Valve - Remove and Install" for the correct procedure.
Illustration 2 g06136408
The Angle (Y) should be 43 degrees. The Angle (Z) should be 18 degrees
Position key (35) on the shaft on fuel injection pump (19) in the position as shown in Illustration 2
Install a new O-ring seal (28) to fuel injection pump (19). Ensure that the O-ring seal is correctly installed to the groove in the fuel injection pump.
Illustration 3 g03674811
Use Tooling (A) to rotate the crankshaft so that number one piston is at Top Dead Center Position on the compression stroke.
If necessary, install Tooling (B) to the lock the crankshaft in the correct position.Note: Do not use excessive force to install Tooling (B). Do not use Tooling (B) to hold the crankshaft during repairs.
Remove Tooling (B) from the crankshaft. Use Tooling (A) to rotate the crankshaft in a counter clockwise direction by 80 degrees. Refer to Illustration 3 for the correct positioning.
Illustration 4 g06136413
Illustration 5 g06131558
Illustration 6 g06136427
Inspect the bore in front housing (29) for damage. If the bore is damaged, replace the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove" and Disassembly and Assembly, "Housing (Front) - Install" for the correct procedure
Carefully install fuel injection pump (19) to front housing (29). Ensure that the bore in the front housing is not damaged as the fuel injection pump is installed.Note: The fuel injection pump should be supported by hand as the bolts are installed.
Ensure that key (35) aligns correctly with fuel injection pump gear (3). Ensure that the fuel injection pump gear is correctly seated onto fuel injection pump shaft (4). Ensure that the key is not dislodged from fuel injection pump shaft (4) as fuel injection pump (19) is installed into the front housing (29).
Install bolts (30) to fuel injection pump (19) hand tight.
Install a new spring washer (6) (not shown) and install nut (5) hand tight.
Illustration 7