273507 Volvo.Penta Diode

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 5P-7306 Housing 1
5P-7305 Engine Turning Tool 1
B 230-6284 Timing Pin (Camshaft) 1
C 136-4632 Timing Pin (Crankshaft) 1
268-1966 Adapter 1
D 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.
Illustration 1 g02717945
If necessary, use Tooling (A) to ensure that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.
Ensure that Tooling (B) is installed in Hole (Y) in the cylinder block. Use Tooling (B) in order to lock the crankshaft in the correct position. Note: Do not use excessive force to install Tooling (B). Do not use Tooling (B) to hold the crankshaft during repairs.
Illustration 2 g02712440
Alignment of timing marks
Ensure that Tooling (C) is installed into Hole (X) in camshaft gear (1).
Illustration 3 g02718564
Clean idler gear (3) and inspect the idler gear for wear or damage. Refer to Specifications, "Gear Group (Front)" for more information. If necessary, replace the idler gear.
Clean hub (11) and inspect the hub for wear or damage. Refer to Specifications, "Gear Group (Front)" for more information. If necessary, replace the hub.
Lubricate hub (11) with clean engine oil. Slide hub (11) into idler gear (3). Ensure that the timing marks are toward the front of the idler gear.
Illustration 4 g02718572
Align the timing mark on idler gear (3) with the timing mark on the camshaft gear. Refer to the illustration 2. Install the assembly of idler gear (3) and hub (11) into the recess in the timing case. Ensure that oil Hole (Z) is to the top of the hub. Note: The idler gear must be tilted during installation. Ensure that the holes in the hub are aligned with the holes in the cylinder block.
Clean plate (9) and inspect the plate for wear or damage. If necessary, replace the plate.
Lubricate plate (9) with clean engine oil. Align the holes in plate (9) with the holes in hub (11). Install the plate in the original orientation.
Install bolts (10).
Remove Tooling (B) and Tooling (C). Note: Ensure that timing marks are aligned, before removing Tooling (B) and Tooling (C).
Tighten bolts (10) to a torque of 44 N m (32 lb ft).
Use Tooling (D) in order to measure the end play of the camshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.
Use Tooling (D) in order to measure the backlash between the idler gear and the camshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.
Use Tooling (D) in order to measure the backlash between the idler gear and the crankshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.
Illustration 5 g02712439
Install a new O-ring seal (4) to plug (5). Install plug (5) to the cylinder block. Tighten plug (5) to a torque of 21 N m (186 lb in).
Lightly lubricate all of the gears with clean engine oil. End By:
Install the fuel injection pump gear. Refer to Disassembly and Assembly, "Fuel Pump Gear - Install".
Adjust the engine valve lash. Refer to System Operation, Testing and Adjusting, "Engine Valve Lash - Inspect/Adjust" for the correct procedure.