24425969 Volvo.Penta Shim

Preparatory Operations
(a) Stop the fuel supply and disconnect the staring system.(b) Loosen the drain cocks at the rear of the left- and right-hand sides of the crankcase and allow the coolant to drain out.(c) Loosen the drain plug on the oil pan and allow the engine oil to drain out.(Oil pan capacity: 6.3 liters (1.7 U.S. Gallons))
Hot oil can give severe burns. Be careful not to touch it.
Remove Accessories
(1) Removing Fan
(a) Reduce the tension applied by tension pulley by pushing the alternator toward the engine, then remove the water pump drive belt (1).(b) Remove the fan mounting bolts (2), then remove the fan (3) and the fan spacer (4).(c) Remove the water pump pulley (5), which was previously retained by the fan mounting bolts (2).
Removing fan(2) Removing Thermostat Fitting
(a) Remove the water hose (1).(b) Removing the water outlet fitting (2), then remove the thermostat (3) and thermostat fitting (4) in that sequence.(c) Remove the thermo switch (5) from the cylinder head.
Removing thermostat fitting(3) Removing Exhaust and Intake Manifolds
(a) Remove the exhaust manifold mounting bolts, then remove the exhaust manifold (1) and the gasket (2).(b) Remove the intake manifold mounting bolts, then remove the intake manifold (3) and the gasket (4).
Removing exhaust and intake manifolds
When refitting manifolds, fit each gasket with the side marked "MANIFOLD" facing the manifold.(4) Removing Water Pump
Remove the water pump mounting bolts, then remove the water pump (1).
Removing water pump(5) Removing Alternator
(a) Disconnect the battery cables.(b) Disconnect the lead from terminal B at the rear of the alternator.(c) Remove the alternator connector.(d) Loose the alternator adjusting bolt (1) and support bolt (2), then push the alternator toward the engine and remove the fan belt.(e) Remove the alternator.
Removing alternator(6) Removing Starter
(a) Disconnect the battery's (-) and (+) terminals in that sequence.(b) Disconnect the starter wiring (1).(c) Remove the starter's two mounting bolts (2), then remove the starter (3).
Removing starter(7) Removing Oil Filter
(a) The oil filter (2) must be replaced every 100 hours of use.(b) Remove the oil filter using a filter wrench (1).
Removing oil filter(8) Removing Fuel Filter
(a) Remove the fuel hose (1) that leads to the fuel injection pump.(b) Remove the fuel filter (2) from the engine.
Removing fuel filter(9) Removing Fuel Pipes
(a) Remove the clamps from the four fuel pipes (1), then disconnect the fuel pipes from the engine and from the injection pump.(b) Remove the lock nuts (2) and the fuel leak-off pipe (3) from the injection nozzle.
Removing Fuel Pipes
To keep dirt out of the fuel system, fit rubber caps over the parts of the injection pump and injector inlet connectors from which the injection pipes are disconnected.
(10) Removing Injection Pump
Removing Injection Pump(1) Fuel hose(2) Fuel pipe(3) Tie rod cover(4) Tie rod spring(5) Tie rod(6) Injection pump(7) Adjustment shim(8) Control rack pin(a) Remove the tie rod cover (3).(b) Using long-nosed pliers, remove the tie rod spring (4) from the control rack pin (8) and from the governor lever pin.(c) Remove the tie rod (5).
Removing tie rod(d) Remove the injection pump (6) and the adjustment shim (7).
Removing injection pump(11) Removing ETS Solenoid
Loose the nut (1) and remove the ETS solenoid (2).
Removing ETS solenoid(12) Removing Oil Pump
Remove the oil pump's four mounting bolts, then remove the oil pump (1).
Removing oil pump(13) Removing Injection Nozzle
(a) Remove all lock nuts (1) (4 pieces).(b) Remove fuel leak-off pipe (2) and fuel return gasket (3).(c) Remove fuel injection nozzle (4) and holder gasket (5).
Removing injection nozzleRefitting Accessories
General Points
Refit accessories by following the removal procedures in reverse. After refitting accessories, perform the following:(1) Pour the specified amount of engine oil into the engine.(2) Pour coolant into the coolant system.(3) To facilitate starting, pour engine oil into the governor's hydraulic oil filter via the hole of the air bleeding plug.(4) Make sure no oil or coolant is leaking from joints and connections.(5) Air-bleed the fuel system.(6) After refitting the injection pump (see the instructions below), be sure to inspect and adjust the injection timing.Installing Injection Pump
Installation should be performed basically by following the removal procedure in reverse. The following operations must also be performed.(1) Bleeding Air from Fuel System
Bleeding air from fuel system(a) Feed fuel to the engine by turning the key to the ON position. Then, loosen the air vent screw (1), allow air in the filter to be expelled, and retighten the screw.(b) Loosen air vent screws (2) and (3) on the injection pump in that sequence to bleed air from the fuel pipe and injection pump.(c) When air-bleedi