840124 Volvo.Penta Intermediate lever

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0074 Slide Hammer Puller 1
8B-7557 Threaded Adapter 1
B 138-7573 Link Bracket 2
C 1P-0520 Driver Group 1
D - Guide Stud
3/8-16 by 6 2 Start By:
Remove the electronic control module. Refer to Disassembly and Assembly, "Electronic Control Module - Remove and Install".
Remove the alternator. Refer to Disassembly and Assembly, "Alternator - Remove and Install".
Remove the crankshaft front seal and the wear sleeve. Refer to Disassembly and Assembly, "Crankshaft Front Seal and Wear Sleeve - Remove".
Remove the accessory drive (front). Refer to Disassembly and Assembly, "Accessory Drive (Front) - Remove".
Remove the engine oil and water pump drive. Refer to Disassembly and Assembly, "Engine Oil and Water Pump Drive - Remove".
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01388988
Remove bolts (4) and the washers. Remove elbow (3), tube (2) and the O-ring seals.
Remove bolts (8) and the washers that hold shaft (7) in front drive housing (1). Use Tooling (A) to remove shaft (7). Remove the O-ring seal from shaft (7). Remove idler gear (6).
Use Tooling (C) and a suitable press in order to remove the bearing from idler gear (6), if necessary.
Install Tooling (B) and attach a suitable lifting device to front drive housing (1). The weight of front drive housing (1) is approximately 160 kg (352 lb). Remove two bolts and install Tooling (D). Remove the rest of bolts (5) that hold front drive housing (1) to the cylinder block. Remove bolts (9) from the engine oil pan. Remove front drive housing (1) and the gaskets. Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
B 138-7573 Link Bracket 2
C 1P-0520 Driver Group 1
D - Guide Stud
3/8-16 by 6 2
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 2 g01388988
Install the gasket for front drive housing (1) onto the cylinder block. Install the gasket on the oil pan. Install Tooling (D) into the cylinder block.
Install Tooling (B) and attach a suitable lifting device to front drive housing (1). The weight of front drive housing (1) is approximately 160 kg (352 lb). Position front drive housing (1) onto Tooling (D).
Install bolts (5) that attach front drive housing (1) to the cylinder block. Tighten the bolts evenly. Cut any excess gasket from the face of the cylinder block. Position the gasket between the engine oil pan and front drive housing (1). Install bolts (9).
If the bearing was removed from gear (6), use Tooling (C) to install the bearing. After the bearing is installed, measure the bore of the bearing. The bore of the bearing must be 90.0 0.06 mm (3.54 0.002 inch).
Coat the bore for the O-ring seal with clean engine oil. Install the O-ring seal on shaft (7).
Place the washer and gear (6) into position in front drive housing (1). Install shaft (7). Install the washers and bolts (8) for shaft (7).
Install the O-ring seals, tube (2), and elbow (3). Install the washers and bolts (4). End By:
Install the engine oil and water pump drive. Refer to Disassembly and Assembly, "Engine Oil and Water Pump Drive - Install".
Install the accessory drive (front). Refer to Disassembly and Assembly, "Accessory Drive (Front) - Install".
Install the crankshaft front seal and the wear sleeve. Refer to Disassembly and Assembly, "Crankshaft Front Seal and Wear Sleeve - Install".
Install the alternator. Refer to Disassembly and Assembly, "Alternator - Remove and Install".
Install the electronic control module. Refer to Disassembly and Assembly, "Electronic Control Module - Remove and Install".