860866 Volvo.Penta Filler cap

Illustration 1 g01106267
Front gear group
(1) Timing marks
(2) Camshaft gear
(3) Adjustable idler gear
(4) Idler gear
(5) Cluster gear
(6) Timing marks
(7) Crankshaft gear
(8) Oil pump gearThe correct fuel injection timing and valve mechanism operation is determined by the alignment of the front gear group timing. Timing marks (1) and timing marks (6) are aligned in order to provide the correct relationship between the piston movement and the valve movement.Required Parts
Used for properly setting backlash on engines.
Tools are based on idler gear tooth count and gear bushing diameter
Used to allow the correct cam gear backlash to be set for any cylinder head (new or re-machined)
Provides easy access to fasteners on the adjustable stub shaft for setting the correct backlash adjustments.
Set before idler gear is installed into place
Table 1
Part Number Description Gear Bore Diameter (mm) No. of Gear Teeth
374-3473(1) Gear Segment Tool 50.86 mm (2 inch) 56
421-7202(2) Gear Segment Tool 51.41 mm (2.02 inch) 51
462-5095(3) Gear Segment Tool 50.86 mm (2 inch) 51
(1) For use with the 130-4701 Gear As
(2) For use with the 361-8238 Idler Gear As
(3) For use with the 417-4617 Idler Gear As 434-3868 Plate - Used to hold the gear segment tool in place and prevent the segment tool from rotation when checking backlash of cam gear.
Illustration 2 g03870106Setting Backlash for Camshaft and Adjustable Idler Gear
The camshaft gear will be off a half tooth if the engine is timed when Cylinder # 6 is at Top Dead Center (TDC). The engine MUST be timed when Cylinder #1 is at TDC. The engine MUST be timed when Cylinder #1 is at Top Dead Center (TDC). Do NOT time the engine with Cylinder #6 at TDC as the camshaft gear will be off a half tooth.Note: The rocker arm bolts must be loosened to remove preload from the camshaft.
Illustration 3 g02685416
Front cover is removed.
With the front cover removed, remove bolts (3), plate (2), and adjustable idler gear (1).
Illustration 4 g02686407
Loosen one bolt and two nuts (4) that secure the stub shaft. Remove the remaining three nuts. The one bolt and two nuts (4) can still be accessed when the gear segment tool is installed.
Illustration 5 g03320498
(5) Timing marks
(6) 374-3473 Gear Gauge
With the flywheel pinned at TDC for cylinder one, align timing marks (5).
Install the cam gear backlash tool onto the stub shaft, as shown. Both sides of the gear segment tool should be engaged with the corresponding gear, as shown. Hand tighten the one bolt and two nuts enough so that slight resistance is felt if the stub shaft is rotated.
Illustration 6 g03870106
The 434-3868 Plate can be installed to hold the gear segment tool in place.
Illustration 7 g02688245
Measure the backlash between camshaft gear (2) and gear segment tool (3). When the gear segment tool is held stationary, the backlash between the gears is 0.356 0.254 mm (0.014 0.010 inch). Lightly tap the stub shaft with a soft mallet to move the gear segment tool closer or further away to the cam gear as necessary. This movement will increase or decrease the amount of backlash.
Illustration 8 g02688540
Once the proper backlash is obtained, tighten the nuts and the bolt (4) to a torque of 55 10 N m (41 7 lb ft).
Illustration 9 g02688598
Remove the cam gear backlash tool.