872807 Volvo.Penta Gear

Start By:a. remove rocker shaft assemblies and push rodsb. remove front drive housing 1. Remove the bolts that hold the brackets for shaft (3) to the front of the cylinder block. Disconnect the levers on shaft (3) from the levers on shafts (1) and (2), and remove shaft (3) from the engine. 2. Remove levers (5) and (6) and brackets (4) from shaft (3). 3. Remove bearings (7) from brackets (4) with tool group (A). 4. Remove access covers (8) from over the camshafts. 5. Remove the bolts and caps (10) that hold the levers of rod assemblies (9) to fuel control shafts (1) and (2).6. If necessary, remove the cover from the front right side of the flywheel housing, and use tool (B) to turn the engine flywheel until the camshaft is moved in a position so the levers of rod assemblies (9) can be removed between the cylinder block and camshaft 7. Remove bolts (12), and remove lever assemblies (11) and fuel control rod assemblies (9) as a unit from each cylinder head assembly. See Step 6 if the levers on the lower ends of rod assemblies (9) do not have enough clearance to be removed from the engine. 8. Remove locknut (13) and the washer to remove rod assembly (9) from lever assembly (11). 9. Remove levers (15) from control shafts (1) and (2).10. Remove the rings and washers that hold the control shafts in place in supports (14).11. Remove the bolts and supports (14) from each side of the engine.12. Remove the washer and ring from the control shafts. 13. If necessary, remove bearings (16) from supports (14) with tool group (A). 14. Pull control shafts (1) and (2) out of bracket assemblies (17). Remove the control shafts from the engine.15. Remove the bolts and two bracket assemblies (17) from each side of the engine. 16. If necessary, remove bearings (18) from bracket assemblies (17).Install Fuel Injection Control Linkage
1. Use tool group (A) to install the bearings in brackets (17) until they are in the center of their bores. Check the bore in the bearings after assembly. The bearing bores must be 21.925 0.015 mm (.8632 .0006 in). 2. Install two bracket assemblies (17) on each side of the engine. The control shafts must be installed with the two grooves in the end of the control shafts toward the front of the engine.3. Install control shafts (1) and (2) in bracket assemblies (17). 4. Use tool group (A), and install the bearings in the center of the bores in supports (14). Check the bore in the bearings after assembly. The bearing bores must be 21.925 0.015 mm (.8632 .0006 in). 5. Install the ring and washer on the control shafts.6. Put supports (14) in position on the control shafts, and install the bolts that hold them.7. Install the other washer and ring to hold the control shafts in place.8. Install levers (15) on each of the control shafts. 9. Connect lever assembly (11) to rod assembly (9). Tighten the nut and bolt that fastens the lever assembly (11) to rod assembly (9) to a torque of 8 2 N m (6 1 lbft). 10. Install lever assembly (11) and rod assembly (9) as a unit in each cylinder head assembly. If necessary, use tool (B) to turn the engine flywheel until the camshaft moves enough to permit the lever of the rod assembly to move into position.11. Make sure lever assembly (11) is engaged correctly with the fuel injection pump rack, and install the two bolts and washers to hold it in place. 12. Make sure the lever for the fuel control rod assembly is in position on the control shaft, and install the bolt and cap (10).13. Be sure that the seal is in position on the access covers, and install the access covers on the cylinder block. 14. Use tool group (A), and install the bearings in the center of the bores in front control shaft brackets (4). Check the bore in the bearings after assembly. The bearing bores must be 21.925 0.015 mm (.8632 .0006 in). If necessary, make a replacement of the pins in brackets (4). The pins must extend 8.00 0.50 mm (.315 0.200 in) above the surface of brackets (4). 15. Install brackets (4) and levers (1), (5) and (6) on the ends of front control shaft (3). 16. Put shaft (3) in position on the front of the engine. Make sure levers (5) and (15) are engaged correctly, and install the bolts to hold the brackets and shaft (3) to the engine. The clearance between the end of control shaft (2) and lever (5) is 0.20 0.10 mm (0.008 .004 in). After assembly, the control shafts must turn freely by hand, and the linkage must return to the "SHUTOFF" position when it is turned and released. See the Testing And Adjusting Manual for the correct adjustment of the fuel injection control group.End By:a. install rocker shaft assemblies and push rodsb. intall front drive housing