3802144 Volvo.Penta Turbocharger

1. Remove oil line (1), fuel line (2), fuel ratio control line (3). 2. Remove clip (4) and use tool (A) to slide sleeve (5) into the cylinder head. 2. With tooling (B) in place, remove clip and pin (6).3. Remove three bolts (7). Remove the governor with the o-ring seal. Care must be taken not to damage the fuel control linkage. Install in reverse order. After installation, check the Fuel Setting Adjustment. Refer to Systems Operation Testing And Adjusting section of this service manual.Disassemble And Assemble Fuel Transfer Pump
Start By:a. remove governor and fuel transfer pump 1. Install governor on governor repair stand (A).
There is spring force behind cover (1). Hold cover (1) in position, and slowly remove bolts (2), to release the spring force.
2. Remove three bolts (2) and cover (1).3. Remove fitting (3) and check valve (4) from cover (1). Inspect parts for wear.4. Remove spring (5), piston (6) and inspect for wear. Replace the spring and the complete piston assembly if necessary.5. Remove upper o-ring (7).6. Remove sleeve assembly (8). Inspect tappet face (9) for wear. Replace complete assembly if necessary. Inspect cam surface, if damaged, replace the front housing assembly.7. Remove lower o-ring seal (10).8. Remove fitting (11) and check valve (12). Inspect for wear. The following steps are for the assembly of the fuel transfer pump.9. Lightly lubricate fitting (11) and the check valve bore with engine oil. Install the check valve with the sealing face down. With the o-ring in place, install fitting (11).10. Lubricate the sleeve bore. Install lower o-ring seal (10). Apply 8T2998 Camshaft Lubricant to tappet face (9). Slide sleeve assembly (8) into place, aligning the flat on the sleeve with the flat on the housing bore. Install upper o-ring (7).11. Lightly lubricate piston assembly (6) with engine oil. Install piston assembly (6) and spring (5).12. Lightly lubricate fitting (3) and the check valve bore with engine oil. Install the check valve with the sealing face toward the fitting. With the o-ring in place, install fitting (3).13. Position cover (1) compressing spring (4), and install bolts (2).14. Remove governor from tool (A).End By:a. install governor and fuel transfer pumpRemove And Install Fuel Ratio Control
Start By:a. remove the governor The fuel ratio control must be adjusted using the governor calibration bench. It can not be adjusted while it is on the engine.1. Disconnect fuel ratio control line (1). Remove bolt (2) and clamp (3). 2. Remove fuel ratio control assembly (4) by working stem (5) out of fork (6). The following steps are for the installation of the fuel ratio control.
When removing plug (7), care must be taken to avoid damaging the internal parts of the governor.
3. Remove housing plug (7), using the blade of a screwdriver, accessed thru the fuel ratio control assembly location in the governor housing. This exposes adjustment screw (8).4. Install the fuel ratio control assembly, insuring that stem (5) is engaged thru fork (6). [Reach thru the other side to help engage fork (6)].5. Position clamp (3) and install bolt (2).6. calibrate governor, (including the fuel ratio control adjustment), using Special Instruction Form No. SEHS8868 (Using 1U7326 Governor Calibration Bench).
Use care when applying sealant to the plug. The sealant must not be permitted to enter the governor housing.
Apply 5P3413 Sealant to the plug and install the plug in the housing bore. Expand the plug by carefully tapping the center of the plug with a hammer and a blunt ended punch until the plug is tight in the bore.7. install Plug 7C6204 (and Plug 7C6205 if not equipped with fuel ratio control) using Sealant 5P3413.End By:a. install governorDisassemble And Assemble Governor Spring Group
Start By:a. remove shutoff solenoidb. remove governor 1. Mount the governor on governor repair stand (A) positioned on the drive gear end.2. Remove the fitting from cover assembly (2). Remove three bolts (1) and then remove cover assembly (2). Remove o-ring (3).3. Remove rear spring seat (4) (dashpot equipped governors only), shims (5) and spacer (6).4. Remove the spring and seat assembly (9) with springs. Spring (7) can be removed by unscrewing spring coils from molded spring seat (9).5. Remove snap ring (8) and the inner springs from molded spring seat (9). Replace as a spring group package only. Dashpot spring, if governor is so equipped, need not be replaced as part of the governor spring package. The following steps are for the installation of the governor spring group.6. Screw the governor springs onto molded spring seat (9). Visually align springs so that they are square with the seat assembly and each other. Install the spacer, the ring and the snap ring.7. Slide seat assembly (9) and the springs onto the riser shaft with the springs facing up.8. Install the rear spring seat (if applicable), shims (5) and spacer (6). If governor is equipped with dashpot (10), be sure the dashpot piston is piloted in the rear of the spring seat.9. With o-ring (3) removed, lightly lubricate the housing bore with engine oil, and loosely fit the rear cover assembly into place. The oil in the rear cover sump, should be drained.10. Remove the screen assembly in the housing, under the Allen plug, for the purpose of installing tooling (B). Before performing step 11, the low idle adjustment screw MUST be backed out completely (turned counterclockwise) so that the throttle lever contacts the governor housing. The low idle adjustment is made during governor calibration. 11. Install tooling (B) and set the dial indicator probe on the center of the rear cover. To zero the indicator, push the rear cover assembly down until it makes contact with the governor housing and then zero the indicator. Release the cover and as the spring pushes up, rotate it approximately 1/4 turn, then read the indicator. Add or subtract shims (5) to achieve the correct spring preload dimension. Rear cover assembly must move freely. Refer to the Governor Performance Data Fiche for the correct spring preload dimension in MM, according to the governor group number.12. Remove