Volvo Penta — Injection pump, fitting and adjusting
Adjustments
From a Volvo Penta service manual — check it applies to your exact model before use.
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Before you start
- If you turn too far, do not turn back; start again from tappet in bottom position.
Procedure
- Check about 1 litre of engine oil in injection pump and governor (mechanical governors).
- Remove valve cover on 1st cylinder.
- Remove inspection plug on flywheel casing.
- Crank engine until 1st cylinder is on compression (0° flywheel, both valves closed).
- Crank flywheel back approx. 90°, then forwards to correct degrees before the pointer.
- Fit injection pump and bracket; fit attachment screws.
- Make sure pump coupling is clean and oil-free; connect to pump flange.
- Remove hex socket plug to reveal 1st tappet.
- Turn pump coupling until tappet is in bottom position.
- Fit tool 6848 and a dial indicator to the tappet; zero-set the indicator.
- Tighten clamping screw so coupling turns with great resistance.
- Turn coupling against rotation to the required lift value; do not turn back.
- Torque-tighten coupling clamping screw, check reading and adjust if needed.
- Remove tools; fit hex socket plug with new copper washer.
- Connect fuel pipes, fit valve cover and bleed the fuel system.
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Lift from basic circle per Workshop Manual, Technical Data
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.