Volvo 2001 - Fuel Injection and Cooling Systems Assembly

C .
Turn cylinder no . 1 to it's injection . position
. Place the
guide pin (2) in the setting-disc's hole marked cyl
. 1 . Turn
the crankshaft a little against
the normal direction of
rotation and thereafter in the normal rotation direction
until the
setting-disc's guide
pin (2) goes in the timing cover's hole .
Measure using a caliper the distance between the
cylinder
block and the roller
lifter's edge (do not measure on the
roller) .
The distance shouldbe :
2001
:
55 .8
mm
(2 .1 9685
in)
2002, 2003 : 55,6 mm (2 .18504 in)
2003T : 55 .9
mm (2 .2007 in)
Example :
2001
. If the measured distance
is 55 .2 mm
(2
.17323 in)
this
means that a
shim with thickness 0 .6 mm (0 .02362
in)
is to
be placed between the caliper and the
block .
2002, 2003 . If the measured distance is 55 .0
mm (2 .16535
in) this
means that a shim with thickness 0 .6 mm (0 .02362
in) is to be placed between the
caliper and the
block.
Themeasuredshims
thickness (in this example 0 .6 mm) is
to
be stamped into the block as in fig . 15 .
The
total
shim thickness is
foun d
by adding the block's
measurements and the pump's
marking .
Example
The block's measurements

6 (=
0
.6
mm/0 .02362
in)
Thepump's marking

2 ( = 0 .2 mm/0.007874
in)
No .
of shims

0 .8 mm
In
this case choosetwo soft shims 0 .2 and 0 .3
mm
(0 .007874 and 0
.011811
in ) and one hard shim of 0 .3
mm
(0
.011811 in) . Place the hard
shimbetween the two soft
ones
and refit the pump . NOTE! A hard
shim must never be
fitted togetherwith
another hard shim or directly
against
the
block or pump .
Hard
shims are available in thicknesses 0 .3, 0 .6 and 0 .9 mm
(0 .011811, 0 .02362 and 0 .035433
in) .
Soft
shims are available in thicknesses 0 .2 and 0 .3 mm
(0,007874 and 0 .011811 in) .
D . Repeat the procedure
for the other pumps (2002, 2003)
in the
same way as for cylinder 1 .
The setting-disc's marking is
explained under point B .
17 . Fit the injection pump(s) together
with the calculated
shim thickness .
Turn the engine so that the cam for the
pump is not in the lifting position . Check that the
pump's
pin locates in the control rod's
groove and
that the
pump(s)
and the locks markings coincide (see
figure) . Check after
fitting each pump that the control rod operates easily
.
Tighteningtorque
for
the nuts is
20 Nm (2,0 kpm)
(14.7
ft .lbs) . Connect the fuel pipe between the pumps and the
pipe from the fuel filter to the
injection pump . NOTE! The
hole
bolt for the return hose has a smaller through-flow
channel than the others (on later versions
it is marked
'Out") .
18 . Install thefeed
pump and thefuel filter . Also install the
thermostat housing with the thermostat
.
NOTE! Do not
forget the lifting eyelet between the fuel
filter and the
thermostat housing
.