21615274 Volvo.Penta Alternator

Photo shows fuel injection pump removed. Turn the crankshaft until the marks on the crankshaft gear, the camshaft gear and the fuel pump gear are in mesh with the idler gear. The idler gear marks may not be in mesh with the other three gears due to the different speed of rotation of the idler gear.1. Remove fuel injection pump (1) (not shown).2. Remove idler gear (3) and camshaft gear (2). Refer to the topics, "Remove & Install Camshaft Gear" and "Remove & Install Idler Gear" in this module for more information. 3. Remove twelve bolts (4).4. Remove four bolts (5).5. Remove bolts (7) that hold the oil pan to the bottom of the timing case.6. Remove timing gear case assembly (6) and the gasket.
Do not allow the idler gear hub to fall. Make sure the camshaft thrust washer is not lost.
7. Remove the gasket behind the timing gear case assembly. Before installing, clean the surfaces of the mating parts and replace with a new gasket.8. If necessary, remove the crankshaft front oil seal from the timing gear cover and replace with new front oil seal. The following steps are for the installation of the timing case. Make sure the oil pan gasket is not damaged. If it is damaged, remove the oil pan and replace it with a new gasket when the timing case is installed. The front section of the gasket can be replaced without the removal of the oil pan, however extreme care must be taken to prevent possible leaks.9. If the oil pan was removed, install the idler gear to the front of the cylinder block. Use the three bolts of the idler gear to hold it in place. Make sure the oil hole is at the top. Make sure the thrust washer for the camshaft is in position.10. Place the new gasket to the cylinder block. Cut the bottom ends of the gasket to fit correctly. Apply 8T9016 Sealant to the bottom ends of the gasket.11. Position the timing gear case assembly to the cylinder block. Tighten the M8 bolts to a torque of 22 N m (16 lb ft). Tighten the M10 bolts to a torque of 44 N m (33 lb ft). If a new timing case assembly will be installed, the two studs will have to be removed. When installing, apply 9S3263 Thread Lock to the studs.12. If the oil pan has not been removed, install the idler gear hub. Secure the four bolts holding the idler gear hub. Make sure the bottom of the timing case is aligned correctly with the bottom of the cylinder block before the four bolts are secured.13. Position the fan drive assembly and/or the alternator and its mounting bracket to the timing case. Secure the timing case to the cylinder block. If the front support plate was separated from the alternator bracket, make sure the right side of the plate is level with the machined face on the cylinder block where the alternator bracket is positioned.14. Install the lubricating oil pump. Refer to the topic, "Remove & Install Oil Pump" for more information.15. Install the camshaft gear and the idler gear. Refer to the topics, "Remove & Install Camshaft Gear" and "Remove & Install Idler Gear" for more information.16. Install the fuel injection pump. Refer to the topic, "Remove & Install Fuel Injection Pump" for more information.End By:a. install timing gear case cover