940280 Volvo.Penta Spring washer

START BY:a) separation of governor from fuel injection pump housing 1. Remove the fuel injection pumps as follows:a) Remove the protection cap and washer (1). b) Install tool (A) and remove bushing (2) from housing.c) Remove the seal (3). d) Install tool (B).e) Lift the fuel injection pump out of the housing.f) Remove the spacer (4). Keep the spacers (4) and pumps together, and put a mark on them as to their location in the fuel injection pump housing.2. Disassemble the fuel injection pump as follows:a) Remove the bonnet (5), ring (6), spring (7), and check valve (8) from the barrel (9).b) Remove the plunger (10), washer (11), and spring (12) from the barrel (9).
During disassembly and assembly of fuel injection pumps, do not cause damage to plunger surfaces. The barrel and plunger are exactly fitted, and the parts can not be changed with other barrels or plungers.
3. Remove the rack (13).4. Remove the lifters (14). Put identification on the lifters and keep them together with their respective pump and spacers. 5. Remove the camshaft plate (15), bolt and lock. 6. Remove the spring (16) and the gear (17) from the camshaft. 7. Remove the camshaft (19). 8. Remove the camshaft bearings from the fuel injection pump housing with tool (C).9. Remove the two bearings (18) from the fuel injection pump housing.Assemble Fuel Injection Pump Housing
1. Install the camshaft bearings in the fuel injection pump housing with tool (C). Install the bearing and governor end of housing so the lubrication hole in the bearing is in alignment with lubrication hole in housing. Install the camshaft bearings even with outside ends of fuel injection pump housing.
Install the rack bearing in the governor end of the housing with the small holes in the bearing parallel to the vertical centerline of the pump.
2. Install the rack bearing in the governor end of the housing with tooling (F). Install the bearing so it will be .195 .005 in. (4.95 0.13 mm) inside the face of the housing.
Tooling (D) must be used to install the rack bearing in the accessory drive end of the housing. This will put the tab on the bearing in its correct position and install the bearing to the correct depth.
3. Install the rack bearing in the accessory drive end of the housing with tooling (D). 4. Put clean engine oil on camshaft. Install the camshaft in fuel injection pump housing. 5. Put the governor drive gear (1) and spring (2) in position on the camshaft. Install the camshaft plate (3), bolt and lock. 6. Install lifters (4) in their correct positions in the housing. Put clean engine oil on the rack. Install rack (5) in the fuel injection pump housing with the opening in the rack near the governor end of the housing.7. Install the spacers in their respective positions in the housing. When new lifters and pumps are installed, it is necessary to make adjustment of the fuel pump timing. See FUEL INJECTION PUMP TIMING DIMENSIONS SETTING, OFF ENGINE in TESTING AND ADJUSTING.8. Assemble the fuel injection pumps as follows:a) Put clean fuel oil on all parts.b) Install the spring on the barrel.c) Install the washer on the plunger and gear segment. Install the plunger in the barrel.d) Install the spring and check valve in the bonnet.e) Put the bonnet in position on the barrel and install the ring to hold the unit together.f) Install the seal on the bonnet.
Make sure the fuel rack is in the center (zero) position before the fuel injection pumps are installed.
9. Put the rack in the center position with tooling (E) as follows:a) Install location fixture (6) on the fuel injection pump housing.b) Install the gauge (7). Move the gauge (7) to zero. Push the rack (5) against the gauge. c) Install the clamp (8) on pump housing as illustrated. This will keep the rack in the center when the fuel injection pumps are installed. 10. With the rack in the center, install the fuel injection pumps as follows:a) Turn the camshaft until the lobe of the camshaft is down for the pump to be installed.b) Install tool (B) on the pump.c) Put the grooves (9) in the bonnet and barrel in alignment with the groove (10) in the pump gear segment. Put the pump in position so the grooves are in alignment with the guide pins in the housing bore. Install the pump in its correct position in the housing. d) Install bushing (11) over the bonnet. Install tool (B) on the bonnet and push down on tool (B). Tighten bushing (11) by hand until the bushig is even with top of housing. If installation of the bushing can not be made this far by hand, remove it. Remove the pump, put the parts in alignment again and install the bushing again.
If installation of pump is correct, the bushing can be tightened by hand until it is even with face of pump housing.
e) Make a check of the rack travel after each pump is installed as follows:Move clamp (8) away from the end of the rack. Use gauge (7) to measure the rack movement. The total rack movement must be .800 in. (20.32 mm). If the rack can not be moved this distance, the pump gear segment is not in the correct position and the pump must be removed and installed again. f) Remove the tool (B) and tool (E). Install tool (A) and turn retaining bushing to a torque of 150 10 lb.ft. (205 14 N m). Remove tool (A). Install the washers and protection caps for fuel injection pumps.END BY:a) connection of governor to fuel injection pump housingb) install fuel injection pump housing and governorc) adjust governor and set the rack (See GOVERNOR ADJUSTMENTS and FUEL RACK SETTING in TESTING AND ADJUSTING)