3802156 Volvo.Penta Turbocharger

start by:a) separation of governor from fuel injection pump housing 1. Remove protection caps and felt washers (1) from pumps.2. Use wrench (A) to remove the bushings (2) that hold fuel injection pumps into housing. Remove the seals (3).3. Use extractor (B) to remove pumps from the pump housing. Put identification on the injection pumps as to their location in the pump housing.4. Remove the bonnet (4), ring (5), spring (6), and check valve (7) from barrel (8).5. Remove the plunger assembly (11), washer (10), and spring (9) from barrel.
Be careful not to cause damage to plunger assemblies. Keep same cylinder pump and plunger together, the plunger from one pump can not be installed in another pump.
6. Remove the rack (12) from the housing. 7. Remove the spacers (13) and the lifters (14) from the housing. Keep the spacers and lifters together with identification as to their location in the pump housing. 8. Remove two bolts (16), lock, and two sleeves from the gear assembly.9. Remove the gear assembly (15) from camshaft. 10. Remove two bolts, plate (17), and spacer that hold camshaft in position in pump housing. 11. Remove the camshaft from the pump housing. 12. Use tool group (C) to remove the camshaft bearings from the pump housing.13. Remove the bearings for fuel rack from the pump housing.Assemble Fuel Injection Pump Housing
1. Use tool group (C) to install the camshaft bearings in fuel injection pump housing. Install bearing in governor end of housing so oil hole in bearing is in alignment with oil hole in housing. 2. Use tooling (F) to install bearing with a groove for the rack.3. Use tooling (E) to install the other bearing for the rack. 4. Put clean engine oil on the camshaft. Install the camshaft in the pump housing. 5. Install the spacer, plate (1), and two bolts that hold camshaft in place in pump housing. 6. Put the gear assembly (2) in position on end of camshaft. Be sure the rod (3) is in the groove of camshaft. 7. Install the sleeves (4), lock, and two bolts on the gear assembly. 8. Install the spacers (5) with their respective lifters (6) in pump housing. If new lifters and/or pumps are to be installed, make adjustment of fuel pump timing dimension. See SETTING THE INJECTION PUMP TIMING. DIMENSION: OFF ENGINE in 3406 VEHICLE ENGINE, TESTING AND ADJUSTING. 9. Install the rack (7) in the pump housing.10. Assemble the fuel injection pumps as follows: a) Put clean fuel on all parts.b) Install spring, washers, and plunger in the barrel.c) Install the spring, check valve, bonnet, and ring on the barrel.
The plunger from one pump can not be installed in another pump. Do not install the pumps until rack (7) is in center position (centered).
11. Use pointer group (D) to put rack (7) in center position. Push the rack into pointer (D) to get the center position. The rack will be extended .156 in. (3.963 mm) from the end of pump housing (opposite the governor) when rack is in center position. 12. Install fuel injection pumps with extractor (B). Turn the camshaft until lobe of camshaft is down on pump to be installed. Look down the pump and make grooves in bonnet and barrel in alignment with groove (slot) in the pump gear. The groove (slot) of gear must be in line with center of these grooves. Put the pump so grooves are in alignment with guide pins in housing bores. Install the pump in its respective bore in housing. 13. Install seal (8) and bushing (9). Put pressure by hand to extractor (B). Tighten bushing by hand (finger tight only) until bushing is even with top of housing. If bushing can not be installed by hand, remove bushing and pump. Make grooves in alignment and install again.
Do not put force on bushings with a wrench to make them even with pump housing. Pump is not installed correctly if a force has to be used to install bushing.
14. Check the rack movement (travel) after each pump is installed. Total rack movement (travel) must be .800 in. (20.32 mm). See INSTALLATION OF INJECTION PUMPS in 3406 VEHICLE ENGINE, TESTING AND ADJUSTING.15. Tighten the bushing with wrench (A) to 150 10 lb.ft. (205 14 N m). Remove wrench (A) and install felt seals and protection caps.end by:a) connection of governor to fuel injection pump housing.