Volvo Penta — Changing injection pump
Repair & overhaul · Injection pump (23611)
From a Volvo Penta service manual covering: TAD530GE, TAD531GE, TAD532GE, TAD722GE, TAD730G, TAD732GE, TAD733GE, TD520GE, TD720GE, tAd731GE. Check it applies to your exact model before use.
Applies to: Volvo Penta TAD530GE, Volvo Penta TAD531GE, Volvo Penta TAD532GE, Volvo Penta TAD722GE, Volvo Penta TAD730G, Volvo Penta TAD732GE, Volvo Penta TAD733GE, Volvo Penta TD520GE, Volvo Penta TD720GE, Volvo Penta tAd731GE
Before you start
- The pump is spring-loaded; if the tappet is not on the base circle the threads in the engine block can be damaged.
- A delivery pipe which has been removed should be replaced with a new one.
Procedure
- Clean the engine thoroughly before removing the rocker cover.
- Remove the plug and install tool 999 8684; adjust the control rod to stop position.
- Make sure the roller tappet for the pump is on the camshaft base circle.
- Loosen the pump screws a couple of turns and tap the pump gently.
- Remove the shim in the roller tappet and cover the hole.
- Read the EP code from the engine identification plate and enter into Calculation 1.
- Read corrected dimension Ek from Table 3; read L0 from Table 1; read A/100 from the pump.
- Calculate theoretical shim thickness Ts = Ek – (L0 + A/100).
- Read actual shim thickness Ss from Table 2 and slide the shim into place.
- Turn the pump linkage lever to middle position, oil the O-rings and insert the pump.
- Fit the pump flange with the chamfered hole facing the pump and pre-load screws to 5 Nm, then slacken 60°.
- Use socket 11668403 and a torque wrench with gauge to turn the pump counterclockwise to its stop.
- Tighten the flange screws 60°, then alternately 7, 10 and 30 Nm starting with the screw remote from the flywheel.
- Remove tool 999 8684 and check that the fuel rack moves freely.
- Pre-tension the delivery pipe in two stages 5 Nm then 25 ±3.5 Nm; fit new rocker cover gasket.
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Shim thickness Ts = Ek – (L0 + A/100)
- Delivery pipe: 5 Nm then 25 ±3.5 Nm
- Rocker cover: 11 ±1 Nm
Source: Volvo Penta service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.