Manual Volvo Penta 2003 (page 21 of 35) (English)

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Turn

cylinder

it's

injection

position

Place

the

guide

(2)

the

setting-disc's

hole

marked

cyl

. 1 .

Turn

the

crankshaft

little

against

the

normal

direction of

rotation

and

thereafter

the

normal

rotation direction

until

the

setting-disc's

guide

(2)

goes

the timing

cover's

hole

Measure

using

caliper

the

distance

between

the

cylinder

block

and

the

roller

lifter's

edge

(do

not

measure

the

roller)

The

distance

shouldbe

2001

9685

in)

2002,

2003

55,6

.18504

in)

2003T

.2007

in)

Example

2001

the

measured

distance

.17323

in)

this

means

that a

shim

with

thickness

0 .6

.02362

in)

be placed

between

the

caliper

and

the

block

2002,

2003

the

measured

distance

.16535

in)

this

means

that

shim

with

thickness

.02362

in)

placed

between

the

caliper

and

the

block.

Themeasuredshims

thickness

(in

this

example

mm)

stamped

into

the

block

fig

The

total

shim

thickness

foun

adding

the

block's

measurements

and

the

pump's

marking

Example

The

block's

measurements



6 (=

mm/0

.02362

in)

Thepump's

marking



(

mm/0.007874

in)

shims



this

case

choosetwo

soft

shims

and

.007874

and

.011811

)

and one

hard

shim

0 .3

.011811

in)

Place

the

hard

shimbetween

the

two

soft

ones

and

refit

the

pump

NOTE!

hard

shim

must

never

fitted

togetherwith

another

hard

shim

directly

against

the

block

pump

Hard

shims

are

available

thicknesses

.3,

and

0 .9

.011811,

.02362

and

.035433

in)

Soft

shims

are

available

thicknesses

and

(0,007874

and

.011811

in)

Repeat

the

procedure

for

the

other

pumps

(2002,

2003)

the

same

way

as for

cylinder

The

setting-disc's

marking

explained

under

point B

Fit

the

injection

pump(s)

together

with

the

calculated

shim

thickness

Turn

the

engine

that

the

cam

for

the

pump

not

the

lifting

position

Check

that

the

pump's

pin locates

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

(2,0

kpm)

(14.7

.lbs)

Connect

the

fuel

pipe

between

the

pumps

and

the

pipe

from

the

fuel

filter

the

injection

pump

NOTE!

The

hole

bolt for

the

return

hose

has

smaller

through-flow

channel

than

the

others

(on

later

versions

marked

'Out")

Install

thefeed

pump

and

thefuel

filter

Also

install

the

thermostat

housing

with

the

thermostat

NOTE!

not

forget

the

lifting

eyelet

between

the

fuel

filter

and

the

thermostat

housing

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Volvo Penta 2003 Manual

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