840135 Volvo.Penta Housing

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 9U-7336 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
(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 g06327243
If necessary, use Tooling (A) to ensure that number one piston is at top dead center on the compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No.1 Piston". for the correct procedure.
Ensure that Tooling (C) is installed in hole (Y) in the cylinder block. Use Tooling (C) to lock the crankshaft in the correct position.Note: Do not use excessive force to install Tooling (C). Do not use Tooling (C) to hold the crankshaft during repairs.
Illustration 2 g06327245
Ensure that Tooling (C) is installed into hole (X) in gear (1).
Illustration 3 g06327249
Clean idler gear (8) and inspect idler gear (8) for wear or damage. Refer to Specifications, "Gear Group (Front)" for more information. If necessary, replace idler gear (8).
Clean hub (14) and inspect hub (14) for wear or damage. Refer to Specifications, "Gear Group (Front)" for more information. If necessary, replace hub (14).
Illustration 4 g06327106
Lubricate hub (14) with clean engine oil. Install hub (14) into idler gear (8). Ensure that the timing marks are toward the front of the idler gear.
Illustration 5 g06327255
Illustration 6 g06327092
Align the timing mark on idler gear (8) with the timing mark on camshaft gear (1) and engine oil pump gear (2). Install the assembly of idler gear (8) and hub (14) 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 (12) and inspect the plate for wear or damage. If necessary, replace plate (12).
Lubricate plate (12) with clean engine oil. Align the holes in plate (12) with the holes in the hub. Install plate (12) in the original orientation.
Install bolts (13).
Remove Tooling (B) and Tooling (C).Note: Ensure that timing marks are aligned, before removing Tooling (B) and Tooling (C).
Tighten bolts (13) to a torque of 44 N m (32 lb ft).
Use Tooling (D) to measure the end play of camshaft gear (1). Refer to Specifications, "Gear Group (Front)" for more information.
Use Tooling (D) to measure the backlash between idler gear (8) and camshaft gear (1). Refer to Specifications, "Gear Group (Front)" for more information.
Use Tooling (D) to measure the backlash between idler gear (8) and the crankshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.
Illustration 7 g06327258
Install a new O-ring seal (3) to plug (4). Install plug (4) to the cylinder block. Tighten plug (4) to a torque of 21 N m (186 lb in).
Lubricate the teeth of the gears with clean engine oil.End By:
Install the valve mechanism cover.
Install the front cover.