This problem is a common one. Someone tried to install injector pump/s on Volvo Penta
2001/2002/2003 , 2000 series diesel
without lining up the pin on the pump with the slot in the "control rod" (part #42) which results in bending the "link rod" (part #41). The control rod if bent is easily removed and flattened but the link rod is very difficult to figure out, and a replacement is $200/backordered/may not be available, from Volvo.
The diagram of the regulation system "governor" ...I am using can be found here: https://www.marinepartseurope.com/en...-23-11653.aspx
(All of the 2001/2002/2003 models should be very similar).
Hours or days spent disassembling & testing, now finally control rod moves fairly smoothly, but still not running right. My case is one where a previous mechanic
gave up on it, so I do not really know if the pumps are shimmed correctly, or how it was initially shimmed.
****The symptoms are the engine starts but after 5-10 seconds revs to 2000rpms and will go higher but not lower. The throttle lever doesn't reduce rpms, even though if the 30mm brass plug
in the block is pulled, the throttle lever moving back towards idle does move the control rod back to the correct location. The fuel
cutoff lever works to shut down engine but can't be used to reduce rpms.
Also the injector pump
shims (used to set the timing) are possibly off, (or unknown) the block is I believe marked 10. One pump possibly 11, another possibly marked 12. also on the pumps I see 451 marked on one & possibly 4 on another. Photos attached below, look at full size and zoom in on last image to see the "451" marking.
Anyone have experience with where on the pumps these markings should be?
New shims are ordered & here in a few days.
So should I be shimming to around 2.1-2.2mm ?? That seems high based on examples in the book... Or maybe 1.4mm ? I currently have 1 old hard shim aprox .9-.9mm (measured) and 2-3 (have tried lots of combinations) soft shims of .2 &.3mm on each pump....
Could my pump timing be way off? The engine runs normally without smoke or bad noises just won't go below 2000rpms, except for just before it is killed with the fuel
cutoff lever. Shim/timing issue...or is this more likely a governor/regulator/etc issue?
The repair manual can be downloaded online... and has a brief section on injection pump shims/setting timing but nothing really on the whole governor/regulation system.
This post and also the following one were helpful in understanding the system
It would be great if there were a simple modification to get rid of this whole system and use cables
, (forget about the cold start advance/procedure)...but I can't see any way to do that either!
Injection pump info plate... at the bottom both pumps marked "UT=58.3 + 0,8" ....if that means anything. both pumps are identical with the same part #
"12" marking on pump:
"11" marking on pump:
small "451" marking on pump..other pump has a very faint 4 in a similar spot:
Anyone care to take a guess as to how these should be shimmed? Any advice & thoughts, or help greatly appreciated!