3861211 Volvo.Penta Cable harness

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
B 230-6284 Timing Pin (Camshaft) 1
C 230-6283 Timing Pin (Crankshaft) 1
E 9U-7324 Indicator Bracket 1
7H-1942 Dial Indicator 1
3S-3268 Indicator Contact Point 1
7H-1940 Universal Attachment 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Note: The fuel injection pump must remain locked until the procedure instructs you to unlock the fuel injection pump.
Ensure that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Finding Top Center Position for No. 1 Piston". Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
Illustration 1 g01343058
Typical example
Ensure that Tooling (C) is installed in hole (Y) in the front housing. Use Tooling (C) in order to lock the crankshaft in the correct position. Note: Do not use excessive force to install Tooling (C). Do not use Tooling (C) to hold the crankshaft during repairs.
Ensure that Tooling (B) is installed into hole (X) in camshaft gear (1).
Ensure that shaft (9) on the fuel injection pump is clean, dry and free from damage.
Ensure that the fuel injection pump is locked in the correct position. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install".
Ensure that the fuel pump gear is clean, dry and free from wear or damage. If necessary, replace the fuel pump gear.
Illustration 2 g01335384
Alignment of timing marks
Install fuel pump gear (3) to shaft (9) of the fuel injection pump. Ensure that the timing marks on gears (2) and (3) are in alignment and that the mesh of the gears is correct.
Illustration 3 g01343060
Typical example
Illustration 4 g01320629
Typical example
Install a new spring washer (10) and install nut (8) to shaft (9) of the fuel injection pump. Apply sufficient pressure to the fuel injection pump gear (3) in a counterclockwise direction in order to remove the backlash. Tighten nut (8) to a torque of 24 N m (17 lb ft). Unlock fuel injection pump (5). In order to unlock the fuel injection pump, loosen locking screw (6) on the fuel injection pump. Rotate spacer (7) in order to allow locking screw (6) to tighten against the spacer. Tighten the locking screw against the spacer to a torque of 17 N m (13 lb ft). This will prevent the locking screw from tightening against the shaft of the fuel injection pump.
Remove Tooling (B) and (C).
Tighten nut (8) to a torque of 88 N m (65 lb ft).
Use Tooling (D) to measure the backlash of gears (2) and (3). Ensure that the backlash for the gears is within specified values. Refer to Specifications, "Gear Group (Front)" for further information.
Lubricate the teeth of the gears with clean engine oil. End By:
Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".