1545022 Volvo.Penta Stud

Start By:a. remove fuel injection pumpsb. disassemble governorc. remove fuel transfer pump 1. Loosen screws (1) in the levers, and remove screw (3) in the crossover lever. Slide shaft assembly (2) out of the housing. 2. Loosen the screws in levers (4), and remove the screw in crossover lever (5). Slide shaft (6) out of the housing. Put identification marks on lifters (7) and rollers (8) for installation in their respective bores in the housing.3. Use a magnet to remove eight lifter assemblies (7). 4. Remove roller (8) from each lifter assembly. 5. Turn the camshaft so the groove (slot) for the timing pin is in the position shown, and carefully remove camshaft (9). Remove the thrust washer from the housing. 6. Remove camshaft rear bearing (10) from the fuel pump housing. Be careful not to damage the bearing bore in the housing. 7. Use tool group (A) to remove the camshaft front bearing from the fuel pump housing.Assemble Fuel Injection Pump Housing
Put clean fuel on all parts during assembly.1. Use tooling (A) to install the camshaft front bearing in the housing. Install the bearing with the chamfer toward the inside of the pump housing.2. Install the bearing so it is even with the front face of the pump housing. 3. Use tooling (B) to machine the bore in the camshaft front bearing to the correct size. See Special Instruction, Form No. SMHS6735, for the procedure to machine the new camshaft front bearing. The bore in the bearing must be 25.413 0.013 mm (1.0005 .0005 in.). 4. Use tooling (A) to install the camshaft rear bearing in the housing. Install the bearing so groove (1) in the bearing is in the position shown. On earlier pump housings without a thrust washer, install the bearing into the bore so the outer face of the bearing is 0.114 0.025 mm (.0045 .0010 in.) below face (X) on the housing. On later pump housings with a thrust washer, install the bearing into the bore so the outer face of the bearing is 0.43 0.13 mm (.017 .005 in.) below the counterbore for the thrust washer. 5. Install thrust washer (2) in the housing with the ear on the thrust washer in the hole in the pump housing so the thrust washer will not turn.6. With the pump housing in a vertical position as shown, carefully install camshaft (3). To make sure that the thrust washer will be kept in its correct installation location, keep the pump housing in a vertical position, and install the fuel transfer pump and camshaft sleeve. See the topic, Fuel Transfer Pump Installation, for the procedure to install the fuel transfer pump and camshaft sleeve.
If the pump housing is assembled while it is in a horizontal position, the thrust washer can slide out of the counterbore and into the area between the camshaft thrust face and the housing. Then the fuel pump camshaft end play will not be correct, and it will be necessary to disassemble the fuel pump housing so the thrust washer can be installed correctly.
7. Install each roller (4) in their respective lifters. 8. Use a magnet to install lifter assemblies (5) in their respective bores in the pump housing with the groove in each lifter in alignment with the dowel in the lifter bore. 9. Install shaft (6) in the pump housing; then through one lever (7); then through crossover lever (8); then through three levers (7) as shown. Install the screw in crossover lever (8). Tighten the screw in crossover lever (8). Tighten the screw to a torque of 2.70 0.25 mm (24 2 lb.in.). Do not tighten any of the screws in the levers. 10. Install shaft assembly (9) in the pump housing; then one lever (11); then through crossover lever (10); then through three levers (11) as shown. Install the screw in crossover lever (10). Tighten the screw to a torque of 2.8 0.2 mm (24 2 lb.in.). Do not tighten any of the screws in the levers.11. After installation of the governor, fuel injection pumps and fuel transfer pump, adjust the fuel pump calibration, the crossover levers, the fuel setting and the high and low idler speeds. See Testing And Adjusting.End By:a. assemble governorb. install fuel injection pumpc. install fuel transfer pump