3809732 Volvo.Penta Wiring harness

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A (1)     9U-6198     Crankshaft Turning Tool     1    
A (2)     9U-7336     Housing     1    
5P-7305 Engine Turning Tool     1    
B     230-6284     Timing Pin (Camshaft)     1    
C     230-6283     Timing Pin (Crankshaft)     1    
D     1U-6396     O-Ring Assembly Compound     1    
( 1 ) The Crankshaft Turning Tool is used on the front pulley.
( 2 ) This Tool is used in the aperture for the electric starting motor.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Inspect the bore in the front housing for damage. If the bore is damaged, replace the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove" and Disassembly and Assembly, "Housing (Front) - Install".
Illustration 1 g01350306
Typical example
Use Tooling (D) in order to lubricate O-ring seal (10) . Install a new O-ring seal (10) onto fuel injection pump (4) .
Install new washers (9) to bolts (8) .
Align the holes in the fuel injection pump with the holes in the front housing. Install fuel injection pump (4) to the housing.Note: The fuel injection pump should be supported by hand until the bolts are installed.
Install bolts (8) . Tighten bolts (8) to a torque of 22 N m (16 lb ft).
Position support bracket (11) onto the cylinder block. Install bolt (14) finger tight.
Install bolt (12) and nut (13) finger tight.
Tighten bolt (12) and nut (13) to a torque of 22 N m (16 lb ft). Tighten bolt (14) to a torque of 44 N m (32 lb ft). Note: Ensure that the fuel injection pump is not stressed as the bolts for the bracket are tightened.
Ensure that the No. 1 cylinder is at top dead center on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Fuel Injection Timing - Check". If necessary, use Tooling (A) in order to rotate the crankshaft so that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston".Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Use Tooling (B) in order to lock the camshaft in the correct position. Use Tooling (C) in order to lock the crankshaft in the correct position. Refer to Disassembly and Assembly, "Gear Group (Front) - Remove" for the correct procedure.
Install the fuel injection pump gear to fuel injection pump (4) . Refer to Disassembly and Assembly, "Fuel Injection Pump Gear - Install" and refer to Disassembly and Assembly, "Gear Group (Front) - Install".Note: Ensure that the fuel injection pump is in the unlocked position after the installation of the fuel injection pump gear is completed.
Illustration 2 g01350305
Typical example
Remove the plugs and caps from ports and tube assemblies.
Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install".
Connect plastic tube assemblies (1) and (6) to fuel injection pump (4) .
Connect tube assembly (3) to fuel injection pump (4) .
Install tube assembly (2) .
Connect the harness assembly to solenoid (7) . Tighten nut (7) to a torque of 4 N m (35 lb in).
Connect the harness assembly to solenoid (5) .
Turn the fuel supply to the ON position.
Turn the battery disconnect switch to the ON position.End By: Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".