3801370 Volvo.Penta Unit injector

Introduction
Do not perform any procedure in this Special Instruction until you have read this information and you understand this information.This Special Instruction describes the procedure to convert the former pump to the new design with the 321-9740 Pump Kit .The former 164-7735 Gear Pump Gp has been replaced with the new 321-9741 Gear Pump Gp . The new pump uses a mounting flange with four bolts that provides a more rugged connection between the oil transfer pump and the front housing.Disassembly and Assembly Fixture
Refer to Illustration 1 for the materials, the dimensions, and the instructions for fabrication of the disassembly and assembly fixture. All dimensions on the drawing are in inch measurements.
Illustration 1 g01715955
Remove the Former Pump
Illustration 2 g01705076
(3) 217-7028 Spacer As (4) 164-7729 Adapter (5) 0S-1590 Bolt (6) 164-7735 Gear Pump Gp
Remove bolts (5) and remove the old pump (6) from the engine.
Remove spacer (3) and adapter (4) .Pump Disassembly
Illustration 3 g01714283
164-7735 Gear Pump Gp (early versions) (1) Bracket assembly (2) Nameplate (3) Lock washer (4) Nut (5) Stud (6) Shaft (7) Bearing assembly (8) Mechanical seal (9) Retaining ring (10) O-ring seal (11) Separation plate (12) Relief valve
Illustration 4 g01714437
164-7735 Gear Pump Gp (later versions) (1) Bracket assembly (2) Nameplate (3) Lock washer (4) Nut (5) Stud (6) Shaft (7) Bearing assembly (8) Mechanical seal (9) Retaining ring (10) O-ring seal (11) Separation plate (12) Relief valve
For Steps 2 through 10, refer to Illustration 3 or refer to Illustration 4.
Use a scribe or a marking pen to mark the entire length of the top of the pump with a straight line before disassembly in order to ensure proper reassembly. Offset the mark from the centerline of the pump.
Place the pump with the shaft in the downward position through the 84.07 mm (3.31 inch) hole in station "A" of the disassembly and assembly fixture. Remove four nuts (4) and lock washers (3). Discard the lock washers. New lock washers are supplied in the 321-9740 Pump Kit .
Hold the pump together and move the pump to station "B" of the disassembly and assembly fixture. Orient the head of the pump in the downward position with shaft (6) in the upward position. Place relief valve (14) between the two 1 inch blocks in station "B" of the fixture.
Gently tap on the ears of bracket assembly (1) with a soft faced hammer. Pull bracket assembly (1), bearing assembly (7), and studs (5) from the pump assembly. Be extremely careful not to damage shaft (6) .
Document the serial number from pump nameplate (2) on bracket assembly (1). This serial number must be stamped onto the new nameplate that is provided in the 321-9740 Pump Kit .
Remove studs (5) from bracket assembly (1) and discard bracket assembly (1). A new bracket is supplied in the 321-9740 Pump Kit .
Remove mechanical seal (8) and retaining ring (9) from the pump assembly. Discard these components. A new mechanical seal and a new retaining ring are supplied in the 321-9740 Pump Kit .
Remove O-ring seal (10) from separation plate (11). A new O-ring seal is supplied in the 321-9740 Pump Kit .
Clean shaft (6) in the areas of the ball bearing assembly (7) and the mechanical seal (8) .Pump Assembly
The contents of the 321-9740 Pump Kit are listed in Table 1.
Table 1
321-9740 Pump Kit    
Qty     Description     Callout    
1     Ball bearing     10    
1     Bracket     3    
1     Seal     11    
1     Pump nameplate     4    
1     O-ring     16    
1     O-ring     18    
1     Retaining ring     9    
1     Retaining ring     12    
2     Screw     2    
4     Lock washer     5    
1     Bracket assembly     15    
4     Capscrew     1    
Illustration 5 g01715196
321-9741 Gear Pump Gp (1) Capscrew (2) Screw (3) Bracket (4) Nameplate (5) Lockwasher (6) Nut (7) Stud (8) Shaft (9) Retaining ring (10) Ball bearing (11) Seal (12) Retaining ring (13) Head (14) Relief valve (15) Bracket assembly (16) O-ring seal (17) Dowel pin (18) O-ring seal (19) Separation plateFor Steps 8 through 13, refer to Illustration 5.
Before reassembly, ensure that all parts are clean. Replace any worn parts. Ensure that the parts in the 321-9740 Pump Kit are clean.
Align the mark that was made on the top of the pump prior to disassembly.
Place head (13) with relief valve (14) between the two 1 inch blocks in station "B" of the assembly fixture. Orient the shaft end of the pump to the upward position.
Install retaining ring (12) into the groove of shaft (8) for installation of the mechanical seal.
Use SAE 10 oil to lubricate mechanical seal (11). Carefully slide the seal onto shaft (8) .
Lubricate O-ring (18). Install the new O-ring into the groove of separation plate (19) .
Install original studs (7) into new bracke