7744050_017 Volvo.Penta heat exchanger and thermostat with installation comps

1. Remove bolts that hold the timing gear cover to the oil pan (2).2. Remove bolts (1) that hold the timing gear cover to the cylinder block. 3. Install tooling (A) on the timing gear cover as shown.4. Fasten a hoist to the timing gear cover. Loosen the timing gear cover from its dowels with two 3/8"-16 NC forcing screws. Remove timing gear cover (3). Weight of the timing gear cover is 190 lb. (86 kg).Install Timing Gear Cover
If the gasket for the oil pan has damage, remove the oil pan and install a new gasket.1. Install a new gasket on the timing gear cover. Cut the bottom of the gasket even with the bottom of the timing gear cover.2. Put clean SAE 30 oil on the crankshaft and the rubber lip of the crankshaft front seal. 3. Fasten a hoist to tooling (A). Put the timing gear cover (3) in position on the dowels in the cylinder block. Make sure the teeth of the water pump gear (2) engage in the teeth of the camshaft gear (1). Install the bolts that hold the timing gear cover to the cylinder block and the accessory drive housing.end by:a) install power take-offb) install engine front supportc) install water pumpd) install alternatorDisassemble Timing Gear Cover
start by:a) remove timing gear cover. 1. Remove bracket (3). 2. Remove the bearings and spacer for camshaft drive gear with tooling (A). Remove the thrust washer.3. Remove the bearing (2) for power take-off drive gear with tooling (A). Remove thrust washer (1).4. Remove cover (4) for water pump idler gear. 5. Remove the shaft from the idler gear with tooling (B). Remove idler gear (5).6. Remove the plug. Remove the outer bearing for the idler gear with tooling (C). Remove the inner bearing for the idler gear with tooling (D).Assemble Timing Gear Cover
1. Install inner bearing (3) for the water pump idler shaft with tooling (A).2. Install outer bearing (2) for the idler shaft with tooling (B).3. Put the idler gear (1) in the timing gear cover so the side of the gear with the longer hub is toward the rear of the engine.4. Install the shaft (4) through the bearings and gear. Make sure dimension (D) is .188 in. (4.78 mm). 5. Install bearing (5) for the power take-off drive shaft with tooling (C). Install the thrust washer for the shaft over its two dowels.6. Install bearings and spacer for the camshaft drive gear with tooling (C). Make sure the oil holes are in alignment. The projection of bearings must not be more than .03 in. (0.8 mm) past the inside face of the timing gear cover. Install the thrust washer for the camshaft drive gear over its two dowels.7. Install the covers for the camshaft drive and water pump drive.8. Install the bracket for the belt tightener.end by: a) install timing gear coverRemove Camshaft
start by: a) remove valve liftersb) remove timing gear cover 1. Carefully pull camshaft (1) from the cylinder block. The rear of the camshaft shaft can be held up through the inspection cover openings on the right side of the cylinder block.2. Fasten a hoist to the camshaft and remove it, Weight is 100 lb. (45 kg).
Use care not to cause damage to the bearing bores by the cam lobes when the camshaft is being removed.
3. Remove thrust washer (2) from the cylinder block.Install Camshaft
1. Install a new thrust washer (2) on the cylinder block.2. Put clean engine oil on the camshaft bearings. Put graphite grease on the lobes of the camshaft shaft.3. Fasten a hoist to the camshaft (1). Carefully install the camshaft into the cylinder block. Pull the camshaft shaft through the bearings while holding it through the inspection cover openings.4. Put the "C" mark on the large camshaft gear in alignment with the "C" mark on the crankshaft gear.end by: a) install timing gear coverb) install valve liftersDisassemble Camshaft
start by: a) remove camshaft 1. Remove nuts (1), lock and bolts.2. Remove large camshaft gear (2). 3. Remove small camshaft gear (3) with tooling (A).4. Remove the key from under the small gear.Assemble Camshaft
1. Install key (5) in the camshaft (4).2. Heat small camshaft gear (6) to a maximum temperature of 750°F (399°C). Install the gear over the key and shaft.3. Put large camshaft gear (7) in position on the small gear. Install bolts (1), lock (2), and nuts (3) that hold it. Make sure the "C" mark on the large camshaft gear is toward the front of the camshaft.end by: a) install camshaft