862856 Volvo.Penta Tube

Before any service work is done on the fuel system, the outer surface of the injection pump housing must be clean.
The fuel injection pumps can be removed and installed with the fuel injection pump housing on the engine. 1. Disconnect drain line (1) from the elbow on the bottom of the fuel injection pump housing if the fuel injection pump housing was removed from the engine. 2. Install the fuel injection pump housing on tool (A) if it was removed from the engine.3. Remove bolts (2), flanges (3) and cover (4) from the fuel injection pump housing.4. Install tool (B) to turn the camshaft in the fuel injection pump housing. 5. Remove spring (5) and the bypass valve from the pump housing. Put identification on the fuel injection pumps so they will be installed in the same bore in the housing. 6. Turn the camshaft until the lifter for the pump to be removed is at its lowest position. Install tooling (C) on the fuel injection pump and loosen the bushing from the pump housing. Do not loosen screws (6) that hold the levers to the shaft when the pumps are removed or installed. If the levers are moved, fuel pump calibration will be changed.7. Remove the fuel injection pump from the pump housing. The sleeve on the plunger will slide off the lever as the pump is removed.8. Do Steps 6 and 7 for the remainder of the pumps.Install Fuel Injection Pumps
1. Turn the camshaft until the lifter for the pump to be installed is at its lowest position. 2. Install tooling (C) on fuel injection pump (1) and install the fuel injection pump in the bore of the pump housing.3. Sleeve (2) will be engaged with the lever when the pump is installed correctly.
If the levers have been moved on the shaft, fuel pump calibration must be made. See TESTING AND ADJUSTING.
4. Tighten the bushing with tooling (C) to a torque of 82 7 N m (61 5 lb.ft.).5. Do Steps 1 through 4 for the remainder of the pumps. 6. Install bypass valve (4) and spring (3) in the pump housing as shown. 7. Install the gasket and cover (5) on the pump housing. Be sure spring (3) is in the bore in the cover. 8. Put flanges (6) in position on the cover as shown and install the bolts that hold the cover and flanges in place.9. Remove tooling (A) and (B) from the fuel injection pump housing. 10. Connect drain line (7) to the elbow on the bottom of the fuel injection pump housing.Disassemble Fuel Injection Pumps
start by:a) remove fuel injection pumps 1. Remove bushing (1) and seal from bonnet (2).2. Remove ring (3) from the bonnet and barrel (7). Remove check valve (6) and spring (4) from the bonnet.3. Remove spring (8) and washer (5). Remove plunger (9) and sleeve (10). Keep the plunger and sleeve with their respective barrel for installation. Do not use plungers, sleeves and barrels with other plungers, sleeves and barrels.Assemble Fuel Injection Pumps
1. Install sleeve (4), plunger (5), spring (2) and washer (3) on barrel (1). Be sure the sleeve and plunger are installed in their original barrel and the large hole in the plunger is up. The sleeve must be installed with the thin flange up.2. Install the check valve and spring in the bonnet. Connect the barrel and bonnet and install the ring. Install the seal and bushing on the bonnet. a) install fuel injection pumps