Fitting a replacement Bosch High Pressure Fuel Pump (0966 437 423) Volvo OEM No 36002064 to a Volvo Penta D3-200 AG

[Doc Holiday]

I am wanting to fit a new High Pressure Diesel Pump to one of my D£-200 engines. It is a fairly straightforward if awkward procedure but I was wondering if anyone knew of a technique for aligning the pump spigot with the two slots in the drive mechanism between the camshaft and pump assembly? The manual just says tighten each of the 3 bolts a 1/4 turn at a time. I can see this would work as long as the spigot is in the 2 drive slots but as you cannot twist the pump until the spigot engages with the 2 slots (there is a fixed bolt in the way) apart from trial and error is there a way this can be done? I can take a photo from the rear of the engine into the space where the drive mechanism is housed but I cannot physically get to the rear of the engine. The refitting has to be done by feel. I have successfully changed one pump but it was a bit of a struggle. The photo shows the spigot and the fixed bolt - if I could easily remove the fixed bolt I would be able to feel the HP spigot engage with the slots in the drive mechanism but I don't want to risk damaging it.

 

[kashurst]

I would either get a stud extractor and take that stud out making the job a lot easier or put two nuts on the stud and nip them up against each other nice and tight. Unscrew the stud with a spanner on the nut closest to the engine. Then you can jiggle the pump onto the drive spigot.

 

[Doc Holiday]

Thank you Kashurst for your swift reply. I have a stud extractor that clamps on the stud and uses a 1/2 inch drive as well as some spare nuts that I think are the correct size (M8). I am a bit wary about removing the stud although with such a newish engine it should be easy enough. Can you confirm that the thread in the block/cylinder head is likely to be a LH thread - the opposite hand to the end requiring the nut? What method would be your choice - stud removing tool or the 2 nut approach? Many thanks.

 

[JAH]

Surely cannot be LH thread - that would mean it would loosen when the nut on top is tightened down !
Also, that stud remover uses knurlings (teeth) to grip the OD of the stud, so it will probably throw up burrs on the stud. The stud will probably need filing smooth or replacing after that tool is used, to ensure it can slide freely in the pump body during installation. Two nuts may be safer - use two 'long nuts' if possible (ie long enough threaded section) to minimise risk of thread damage during tightenening against each other - any good fastener supplier sells those, eg Namrick.
Good luck.