3825903 Volvo.Penta Housing

Make sure all of the air pressure in the system is released before disconnecting any air lines.
2. Disconnect the hose assemblies from fittings (3) and (4).3. Fasten a hoist to air starter (1). Remove three bolts (2) and the air starter from the flywheel housing. The weight of the air starter is 54 kg (120 lb).4. Remove the gasket from the air starter. The following steps are for installation of the air starter.5. Put the gasket and air starter (1) in position on the flywheel housing, and install bolts (2).6. Connect the hose assemblies to fittings (3) and (4).Disassemble Air Starter
Start By:a. remove air starter Make sure there is a complete set of new gaskets, vanes, seals and O-ring seals before the air starter is disassembled. 1. Remove elbow (1) from cover assembly (2). 2. Remove silencer group (4) from motor housings (3). 3. Put identification marks to show the position of motor housing (3) in relation to gear case (7) for assembly purposes. Remove bolts (5) to remove gear case (7) and drive housing (6) as a unit from motor housing (3). 4. Use tool (A) to remove ring (9) from drive gear (8). This air starter is a right hand model, and bolt (10) has left hand threads. Right hand model is R.H. pinion rotation, as seen from the drive end.5. Remove bolt (10) and washer (11) to remove drive pinion (12), a sleeve and spring from the end of the drive shaft.6. Make alignment marks to show the position of drive housing (6) in relation to gear case (7) for assembly purposes. Remove bolts (13), and remove drive housing (6) from gear case (7). 7. Remove O-ring seal (14) from drive housing (6).
Piston (15) holds a spring under compression. To prevent personal injury, carefully remove the ring that holds the piston in place and release the tension on the spring slowly.
8. Install tooling (B) between drive gear assembly (8) and piston (15). Use a press to compress the piston return spring, and remove the ring that holds the drive shaft assembly and piston in the drive housing. 9. Slowly release the press to remove the force of piston return spring (17). Remove tooling (B) from between the drive gear and piston, and remove ring (16) from the piston. Remove the drive gear, the piston and drive shaft assembly as a unit from the drive housing. Remove piston return spring (17) from the drive housing. 10. Use a 5/16" hex wrench to loosen the drive gear bolt until the threads are free, and remove drive shaft assembly (18) and piston (15) as a unit from drive gear assembly (8). 11. Remove bulkhead (19) from piston (15). 12. Remove O-ring seals (20) from bulkhead (19). 13. Remove ring (21) from piston (15), and remove the piston from drive shaft assembly (18). The air starters used on the "B" model trucks will not have bumper (23.14. Remove O-ring seal (24), bumper (23) and seal (22) from piston (15). 15. Remove ring (33), cup (32), spring (31), driven clutch jaw (30), driving clutch jaw (29), bearing (28), washer (27), lockwasher (26) and bolt (25) from drive shaft assembly (18). Any time ring (34) is removed, a replacement must be made.16. Remove ring (34) to remove bearing (35) from drive shaft assembly (18). 17. Use tool (C) to remove ring (37), and remove bearing (36) from gear case (7). The air starters used on the "B" model trucks will not have bumper (38) and back-up ring (39).18. Remove bumper (38) from drive housing (6).19. Remove back-up ring (39) from drive housing (6). 20. Remove seat (40) and bearing (41) from drive housing (6). 21. Remove seal (42) from drive housing (6). 22. Make alignment marks to show the position of cover assembly (2) in relation to motor housing (3) for assembly purposes. Remove cover assembly (2) and an O-ring seal from motor housing (3). 23. Remove bolt (44) to remove rotor pinion (43) from the rotor shaft. 24. Loosen setscrew (46), and remove nut (45) from the rotor shaft.25. Remove bearing (47) from end plate (48). 26. Remove O-ring seal (49) and end plate (48) from the end of the rotor. 27. Remove vanes (50) from rotor (51). 28. Remove rotor (51) from motor housing (3). 29. Use a press to remove bearing (52) and end plates (53) from rotor (51). 30. Remove bearing (52) from end plate (53). 31. Remove washers (54) from end plate (53). 32. Remove O-ring seals (55) from cylinder (56). 33. Remove cylinder (56) from motor housing (3). Remove the remainder of the O-ring seals from the cylinder.Assemble Air Starter
Clean all parts thoroughly. Put 2S3230 Bearing Lubricant on all bearings and the drive assembly. Put a thin layer of SAE 10W oil on all other parts before assembly. 1. Install O-ring seals (1) on cylinder (2), and install the cylinder in housing (3). Make sure pin (5) is in alignment with opening (slot) (4) in housing (3). 2. Install O-ring seals (6) on cylinder (2). 3. Install end plate (7) on rotor (8). 4. Install O-ring seal (9) on the rotor shaft. 5. Install bearing (10) over the rotor shaft and in the end plate. 6. Install nut (11) on the rotor shaft with the shoulder toward the bearing. 7. Tighten the nut until there is .03 mm to .08 mm (.001 in to .003 in) clearance between the end plate and the rotor. Use a feeler gauge to check the clearance. Tighten bolt (12), and check the clearance again. 8. Install rotor (8) in motor housing (3) with the pinion end of the rotor toward the cylinder alignment pin. Make sure pin (13) is in alignment with the hole in the end plate. 9. Install vanes (14) i