3802080 Volvo.Penta Turbocharger

START BY:a. disassemble governorb. remove fuel injection pumps 1. Remove cover (1) from the fuel injection pump housing. 2. Remove rack (2) from the fuel injection pump housing.
If the original lifters are to be installed in the fuel injection pump housing, put identification marks on them as to their location in the housing.
3. Remove lifters (3) from the fuel injection pump housing. 4. Put the fuel injection pump housing on end on blocks, and use tool (A) to remove snap ring (4) from the camshaft. 5. Use a soft hammer to push the camshaft toward the governor end of the fuel injection pump housing to loosen washer (5) on the camshaft. Remove washer (5). 6. Remove camshaft (6) from the fuel injection pump housing. 7. Remove bearings (7) from the drive end of the fuel injection pump housing. 8. Remove bearings (8) from the governor end of the fuel injection pump housing.Assemble Fuel Injection Pump Housing
Be sure all oil passages are clear and put clean engine oil on all parts before assembly.1. Use tooling (A) to install bearing (2) in the governor end of the fuel injection pump housing with joint (3) toward the top of the fuel injection pump housing. Install the bearing so it is 0.25 0.20 mm (.010 0.008 in.) below the surface of the housing.2. Use tooling (A) to install bearing (1) in the governor end of the fuel injecton pump housing so it is 7.16 0.13 mm (0.282 0.005 in.) below the surface of the housing. 3. Use tooling (A) to install bearing (4) in the drive end of the fuel injection pump housing with the joint in the bearing toward the top of the fuel injection pump housing. Install the bearing so it is 1.00 0.25 mm (0.039 0.010 in.) below the surface of the housing. 4. Install plate assembly (6) of tooling (C) on the drive end of the fuel injection pump housing to install the bearing for the rack. Use clean grease to hold the new rack bearing on driver (5) of tooling (C). Install the driver and bearing in plate assembly (6) with the groove in the driver in alignment with the pin in the plate. Use a hammer to push the bearing into position. The bearing will be installed to the correct depth when the shoulder of the driver is against plate assembly (6).5. Remove tooling (C) from the fuel injection pump housing. The rack bearing must be installed so it is 0.25 0.25 mm (0.010 0.010 in.) below the surface of the housing. 6. Install camshaft (7) in the fuel injection pump housing.7. Put the fuel injection pump housing on end, and put a block under the camshaft. 8. Put washer (9) over the end of the camshaft, and use tooling (A) and a spacer (8) that has an inside diameter of 38.1 mm (1.50 in.) and a length of 31.75 mm (1.250 in.) to push the washer against its seat on the camshaft. The camshaft must have 0.285 0.235 mm (0.0112 0.0093 in.) of end play when the washer is pushed against the cam shoulder. 9. Use tool (B) to install snap ring (10) in the groove in the camshaft.
If the original lifters are to be installed in the fuel injection pump housing, be sure they are intalled in their original locations. New lifters are the same and can be mixed.
10. Install six lifters (11) in the fuel injection pump housing with the groove in the lifter in alignment with the pin in the housing. 11. Install rack (12) in the fuel injection pump housing with the groove in the end of the rack in alignment with the ear (tab) of the rack bearing at the drive end of the fuel injection pump housing. 12. Install the gasket and cover (13) on the fuel injection pump housing.END BY:a. assemble governorb. install fuel injection pumps