Volvo Penta 2002 - Page 21

C .
Tur n cyl i nder no . 1 t o i t ' s i nj ect i on . posi t i on
. Pl ace t he
gui de pi n ( 2) i n t he set t i ng- di sc' s hol e mar ked cyl
. 1 . Tur n
t he cr ankshaf t a l i t t l e agai nst
t he nor mal di r ect i on of
r ot at i on and t her eaf t er i n t he nor mal r ot at i on di r ect i on
unt i l t he
set t i ng- di sc' s gui de
pi n ( 2) goes i n t he t i mi ng cover ' s hol e .
Measur e usi ng a cal i per t he di st ance bet ween t he
cyl i nder
bl ock and t he r ol l er
l i f t er ' s edge ( do not measur e on t he
r ol l er ) .
The di st ance shoul d be :
2001
:
55 . 8
mm
( 2 . 1 9685
i n)
2002, 2003 : 55, 6 mm ( 2 . 18504 i n)
2003T : 55 . 9
mm ( 2 . 2007 i n)
Exampl e :
2001
. I f t he measur ed di st ance
i s 55 . 2 mm
( 2
. 17323 i n)
t hi s
means t hat a
shi m wi t h t hi ckness 0 . 6 mm ( 0 . 02362
i n)
i s t o
be pl aced bet ween t he cal i per and t he
bl ock .
2002, 2003 . I f t he measur ed di st ance i s 55 . 0
mm ( 2 . 16535
i n) t hi s
means t hat a shi m wi t h t hi ckness 0 . 6 mm ( 0 . 02362
i n) i s t o be pl aced bet ween t he
cal i per and t he
bl ock.
The measur ed shi ms
t hi ckness ( i n t hi s exampl e 0 . 6 mm) i s
t o
be st amped i nt o t he bl ock as i n f i g . 15 .
The
t ot al
shi m t hi ckness i s
f oun d
by addi ng t he bl ock' s
measur ement s and t he pump' s
mar ki ng .
Exampl e
The bl ock' s measur ement s

6 ( =
0
. 6
mm/ 0 . 02362
i n)
The pump' s mar ki ng

2 ( = 0 . 2 mm/ 0. 007874
i n)
No .
of shi ms

0 . 8 mm
I n
t hi s case choose t wo sof t shi ms 0 . 2 and 0 . 3
mm
( 0 . 007874 and 0
. 011811
i n ) and one har d shi m of 0 . 3
mm
( 0
. 011811 i n) . Pl ace t he har d
shi m bet ween t he t wo sof t
ones
and r ef i t t he pump . NOTE! A har d
shi m must never be
f i t t ed t oget her wi t h
anot her har d shi m or di r ect l y
agai nst
t he
bl ock or pump .
Har d
shi ms ar e avai l abl e i n t hi cknesses 0 . 3, 0 . 6 and 0 . 9 mm
( 0 . 011811, 0 . 02362 and 0 . 035433
i n) .
Sof t
shi ms ar e avai l abl e i n t hi cknesses 0 . 2 and 0 . 3 mm
( 0, 007874 and 0 . 011811 i n) .
D . Repeat t he pr ocedur e
f or t he ot her pumps ( 2002, 2003)
i n t he
same way as f or cyl i nder 1 .
The set t i ng- di sc' s mar ki ng i s
expl ai ned under poi nt B .
17 . Fi t t he i nj ect i on pump( s) t oget her
wi t h t he cal cul at ed
shi m t hi ckness .
Tur n t he engi ne so t hat t he cam f or t he
pump i s not i n t he l i f t i ng posi t i on . Check t hat t he
pump' s
pi n l ocat es i n t he cont r ol r od' s
gr oove and
t hat t he
pump( s)
and t he l ocks mar ki ngs coi nci de ( see
f i gur e) . Check af t er
f i t t i ng each pump t hat t he cont r ol r od oper at es easi l y
.
Ti ght eni ng t or que
f or
t he nut s i s
20 Nm ( 2, 0 kpm)
( 14. 7
f t . l bs) . Connect t he f uel pi pe bet ween t he pumps and t he
pi pe f r om t he f uel f i l t er t o t he
i nj ect i on pump . NOTE! The
hol e
bol t f or t he r et ur n hose has a smal l er t hr ough- f l ow
channel t han t he ot her s ( on l at er ver si ons
i t i s mar ked
' Out " ) .
18 . I nst al l t hef eed
pump and t hef uel f i l t er . Al so i nst al l t he
t her most at housi ng wi t h t he t her most at
.
NOTE! Do not
f or get t he l i f t i ng eyel et bet ween t he f uel
f i l t er and t he
t her most at housi ng
.
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