3803912 Volvo.Penta Alternator, exch

Table 1
Tools Needed     Quantity    
9S-9082 Engine Turning Tool     1    
Illustration 1 g00769524
Location of timing pins (typical example) (1) Timing hole (2) Timing pin (3) Slot in the camshaft for the timing pin
Remove rear camshaft covers from both sides of the engine.
Find the top center position for the number one piston. Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston" for the correct procedure.Note: When the timing bolt is installed in the flywheel, it is not necessary to remove the No. 1 valve cover in order to find the compression stroke. Both rear camshaft covers must be removed in order to check the timing.
When the timing bolt is installed in the flywheel, look at the rear end of the camshaft. If the timing ring is visible, then the No. 1 piston is on the compression stroke. If the timing ring is not visible, feel the back of the camshaft for the groove. If the groove is at the back of the camshaft, the flywheel must be turned by 360 degrees in order to put the No. 1 piston on the compression stroke.
When the timing bolt is installed in the flywheel and the No. 1 piston is on the compression stroke, remove timing pins (2) from the storage positions.
Install the timing pins through timing holes (1) on each side of the engine. Install the timing pins into groove (3) in the camshaft on each side of the engine. In order to time the engine correctly, the timing pins must fit into the groove of each camshaft.
If the timing pins do not engage in the grooves of both camshafts, the engine is not in time, and one or both camshafts must be adjusted.
Both camshafts are adjusted in the same manner. Refer to "Timing Adjustment" for the procedure to put the camshafts in time with the crankshaft.
If a camshaft is out of time more than 18 degrees (approximately 1/2 the diameter of timing pin out of groove), the valves can make contact with the pistons. This will cause damage that will make engine repair necessary.
Timing Adjustment
Table 2
Tools Needed     Quantity    
9S-9082 Engine Turning Tool     1    
6V-3010 Puller Group     1    
8S-9089 Bolts     2    
5P-1076 Hard Washers     2    Note: The timing must be checked before the timing adjustments are made. Refer to "Timing Check" for this procedure.After the Timing Check procedure is complete, the timing bolt will be engaged in the flywheel. The No. 1 piston will be at the top center (TC) position.
Illustration 2 g00769537
(4) Bolt (5) Rocker shaft
Remove all of the valve covers on the side for the camshaft adjustment. Now, loosen bolts (4) that hold rocker shafts (5) to the valve cover bases until all rocker arms are free from the injectors and the valves.Note: The above procedure must be done before camshaft drive gear (6) is pulled off the camshaft taper.
Remove the covers from the flywheel housing.
Illustration 3 g00769545
Remove bolt (8) and plate (7) from the end of the camshaft.
Install the 6V-3010 Puller Group, two 8S-9089 Bolts, and two 5P-1076 Hard Washers. Loosen drive gears (6) from the taper on the camshafts. Remove the tooling and the gears.
Remove timing pins (2) from the storage position on each side of the engine.
Illustration 4 g00769524
Turn the camshafts until the timing pins can be installed through the engine block and into grooves (3) (slots) in the camshafts.
Put camshaft drive gears (6) in position on the camshafts.
Use hand pressure to turn and hold the camshaft drive gears in the opposite direction of the rotation. This removes all gear clearance (backlash) between the camshaft drive gears and the idler gears.
Install plate (7) on the camshaft in order to hold the camshaft drive gears to each camshaft.
Tighten bolts (8) .Refer to the engine's Specifications manual.
Install the gaskets and covers on the flywheel housing.
Remove timing pins (2) from the camshafts. Install the timing pins in the storage positions. Install covers over the camshafts and timing pins.
Remove the timing bolt from the flywheel housing. Install the 8T-6765 Pipe Plug in the flywheel housing timing hole. Remove the engine turning tool. Install the cover and the gasket.
Be certain that the rocker arms are correctly engaged with the pushrods. Tighten the bolts in order to hold all of the rocker shafts in position.
Make valve lash adjustments to the unit injectors. Refer to Testing And Adjusting, "Valve Lash and Valve Bridge Adjustment" for the correct procedures.