422836 Volvo.Penta Valve, piston cooling

start by:a) remove fuel injection linesb) remove engine hoods 1. Remove turbocharger oil lines (1) from the turbocharger. Remove line (2) from fuel injection pump housing. 2. Disconnect governor control linkage (3) from the governor. 3. Disconnect three fuel lines (4), (5) and (6) from the fuel injection pump. 4. Remove bolts (7) that hold the fuel injection pump housing to the oil manifold for the engine oil cooler. When bolt (8) is removed, don't let the spacer on the back side between the fuel block and the alternator bracket fall under the engine.5. Remove bolt (8) from the alternator bracket and remove the spacer from the back side of the alternator bracket.6. Remove bolt (9) and plug (10) from the timing gear cover. 7. Loosen bolt (11) in the timing gear a maximum of one turn. 8. Loosen three nuts (12) that hold the pump drive to the timing gear plate until the nuts are even with the end of the studs.9. Pull the fuel injection pump housing and pump drive away from the timing gear plate until the timing gear is against the front side of the timing gear plate. 10. Install tooling (A) in the timing gear cover to push the pump drive shaft and loosen the timing gear on the shaft as follows: a) Install tooling (A) in the position shown and tighten the locks to hold the tooling in place.
The tooling must be installed in the position shown so the locks will not damage the water passage in the timing gear cover.
b) Turn the extension counterclockwise to loosen the bolt in the timing gear. As the bolt is loosened it will push against tooling (A) and push the shaft of the pump drive through the timing gear to loosen the timing gear on the shaft.c) Remove tooling (A) from the timing gear cover. Remove the bolt and washer from the timing gear.11. Remove the nuts and remove the pump drive, fuel injection pump housing and governor (13) as a unit from the engine. Weight is 50 lb. (23 kg).Install Fuel Injection Pump Housing And Governor
1. Install the bolt and washer in shaft (1) in the pump drive. Remove the plug from the pump drive housing and install tool (A) in the plug hole. Turn shaft (1) until timing pin (A) engages in the notch in the shaft. Tool (A) will hold the fuel injection pump camshaft in the correct position to set the fuel injection timing of the engine. 2. Put the governor, fuel injection pump housing (2) and the pump drive in position on the engine as a unit. Install the nuts that hold the pump drive to the timing gear plate.
Be extra careful not to damage the O-ring seals when the fuel injection pump housing and governor are installed.
3. Be sure the threads on bolt (3) and the threads in the shaft of the pump drive are not damaged.4. Install bolt (3) and the washer to hold the timing gear on the shaft. Tighten bolt (3) finger tight only. Bolt (3) must be tight enough to hold the gear clearance (backlash) out of the timing gears when the engine is turned but the timing gear must be able to turn on the shaft when the engine is turned to put the No. 1 piston on top center compression position (TDC). 5. Put No. 1 piston at the top center compression position (TDC) with the following procedure: a) Remove plug (4) from the flywheel housing. b) Turn the crankshaft clockwise (as seen from the front of the engine) until a 3/8"-16 NC bolt (5) at least two inches long can be installed through the timing hole in the flywheel housing and into the hole in the flywheel. Never turn the crankshaft backward to install the timing bolt in the flywheel.c) Remove the valve cover. Check to see if both rocker arms for the No. 1 piston can be moved backward and forward by hand. The No. 1 piston is at the top center compression position when the bolt is installed in the flywheel and both rocker arms for No. 1 piston can be moved backward and forward. If both rocker arms can not be moved, the No. 1 piston is not at the top center compression position. Remove the bolt from the flywheel. Turn the crankshaft clockwise (as seen from the front of the engine) one full turn (360°) and install the bolt again.6. With the timing pin in the fuel injection pump housing and the timing bolt in the flywheel, tighten the bolt in the timing gear to a torque of 111 5 lb.ft. (149 7 N m).7. Check the timing as follows: a) Remove both the timing pin and timing bolt.b) Turn the crankshaft clockwise (as seen from the front of the engine) two full turns and install the timing pin and bolt again.c) The timing is correct if both the timing pin and timing bolt can be installed at the same time. The timing procedure must be done again if the timing pin and timing bolt can not be installed at the same time.d) Remove the timing pin and timing bolt when the timing is correct. 8. Install the bolts (6) that hold the fuel injection pump housing to the oil manifold for the engine oil cooler. 9. Install plug (7) in the flywheel housing. 10. Install plug (8) in the fuel injection pump housing. 11. Be sure the O-ring seal is in position on plug (11) and put clean oil on the O-ring seal. Put plug (11) in position in the timing gear cover and install the bolt and washer that hold it in place.12. Put bolt (9) in position in the alternator bracket. Put spacer (10) in position on the back of the alternator bracket and install bolt (9) through spacer (10) and into the fuel block. 13. Connect the fuel lines (12) to the fuel pump drive. 14. Connect the governor linkage (13) to