3803199 Volvo.Penta Cylinder head

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.Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     1P-0510     Driver Group     1    
B     9U-6148     Idler Shaft Puller     1    
C     8T-5096     Dial Indicator Group     1    Idler Gear
Illustration 1 g01261189
Align timing marks (1) on the following components.
Camshaft gear for the fuel injection pump (2)
Camshaft gear (3)
Idler gear (4)
Crankshaft gear (5)
Illustration 2 g00650474
Note: When the idler gear (4) is removed, do not rotate the crankshaft. If the crankshaft is rotated, the top center position of number 1 piston on the compression stroke must be set.
Remove the idler gear (4) .
Inspect the components for wear or damage.
Illustration 3 g00650568
Replace the bushing (7) (not shown) in the idler gear (4) , if necessary. Use Tool (A) in order to remove the bushing from the idler gear.
Illustration 4 g00650570
(6) Idler gear hub (9) 9U-6147 Stud (10) 96-4876 Nut (11) 9U-6146 Sleeve Assembly (12) 8T-4244 Nut
Replace the idler gear hub (6) , if necessary. Use Tool (B) in order to remove the idler gear hub from the cylinder block.Camshaft Gear for the Fuel Injection Pump
Illustration 5 g00653677
(C) 8T-5096 Dial Indicator Group (2) Camshaft gear for the fuel injection pump (13) Camshaft for the fuel injection pumpNote: When the camshaft gear for the fuel injection pump (2) is removed, do not rotate the crankshaft. If the crankshaft is rotated, the top center position of number 1 piston on the compression stroke must be set.
Use Tool (C) in order to check the end play of the camshaft for the fuel injection pump (13) . For more information on the end play of the camshaft for the fuel injection pump, refer to Specifications, "Gear Group (Front)".
Remove the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove".
Remove the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel Transfer Pump - Remove".
Remove the governor weight assembly. Refer to Disassembly and Assembly, "Governor - Disassemble".
Illustration 6 g00653916
Loosen the bolt (14) that secures the bearing retaining ring (15) in position. Rotate the bearing retaining ring at 180 degrees and then tighten the bolt. This will hold the retaining ring away from the bearing.
Illustration 7 g00653747
Remove the camshaft for the fuel injection pump assembly. Check the following items for wear or damage: the cams (16) , the bearings (17) and the gear (2) .
Replace the camshaft for the fuel injection pump assembly, if any of the components are worn or damaged.Note: If the camshaft for the fuel injection pump is replaced, then the fuel injection timing must be set.
In order to remove the camshaft gear, refer to Disassembly and Assembly, "Camshaft - Remove".
In order to remove the crankshaft front gear, refer to Disassembly and Assembly, "Crankshaft Gear - Remove and Install".