3857023 Volvo.Penta Piston, 0.040 in. os

Start By:a. remove timing gear cover
Do not turn the crankshaft with the camshaft gear removed. Damage can be caused to the pistons and valves, or both.
1. Remove three bolts (2) and thrust plate (1). 2. Remove three bolts (4), plate (5) and gear (3). 3. Check the condition of bearing (6) in gear (3). If the part is worn or damaged, replace the part. Use Tool (A) to remove and install bearing (6) in gear (3). 4. Remove bolts (8), plate (9) and gear (7). 5. Check the condition of bearing (10) in gear (7). If the part is worn or damaged, replace the part. Use Tool (A) to remove and install bearing (10) in gear (7). 6. Remove bolts (12), plate (13) and gear assembly (11).7. Check the condition of bearing (14) in gear assembly (11). If the part is worn or damaged, replace the part. Use Tool (A) to remove and install bearing (14) in gear assembly (11).
If the nuts for shaft assembly (15) are loosened, or if shaft assembly (15) is removed or moved in any way, the backlash for the cam gear and idler gear (3) will have to be adjusted at reassembly. Refer to the Testing and Adjusting Manual for additional information.
8. Check the condition of shaft assembly (15). If the bearing diameter of the shaft is worn or damaged, remove the nuts and replace shaft assembly (15) with a new part. For assembly purposes, the torque for the nuts and bolts holding shaft (15) is 47 9 N m (35 7 lb ft).9. Check the condition of shaft assembly (16). If the bearing diameter of the shaft assembly is worn or damaged, remove the bolts and nuts and replace shaft (16) with a new part. For assembly purposes, the torque for the nuts and bolts holding shaft (16) is 47 9 N m (35 7 lb ft). 10. Check the condition of shaft (17). If the bearing diameter of the shaft is worn or damaged use new parts to replace shaft (17) and bolts (18). Do not reuse bolts (18). Tighten bolts (18) to torque of 50 10 N m (37 7 lb ft). 11. Remove bolts (20) and plate (21).12. Remove seal assembly (19) from plate (21). 13. Replace O-ring seals (22) and (23) with new parts on seal assembly (19). The following steps are for the installation of the timing gears and plate.14. Install a new gasket on the back of plate (21).15. Install plate (21) and bolts (20). Evenly tighten bolts (20).16. Position O-ring seals (22), (23) and seal assembly (19) in plate (21). Install bolts (2) into seal assembly (19). Evenly tighten bolts (2) until seal assembly (19) and O-ring seal (22) is seated against the cylinder head. Remove bolts (2). 17. Put gear assembly (11) onto shaft (17) ensure that the "V" timing marks are aligned on gear assembly (11) and the crankshaft gear, as shown. Install plate (13). Install and tighten bolts (12) to a torque of 25 6 N m (18 4 lb ft).18. Put gear (7) onto shaft (16). Install plate (9). Install and tighten bolts (8) to a torque of 25 6 N m (18 4 lb ft).19. Put gear (3) onto shaft (15). Install plate (5). Install and tighten bolts (4) to a torque of 25 6 N m (18 4 lb ft).20. Install three bolts (2) and thrust plate (1).End By:a. install timing gear cover