8170666 Volvo.Penta Plug

start by:a) remove magnetob) remove service meter 1. Remove nuts (1), washers, cover (2) and gasket from the front housing. 2. Remove bolt (3) and washer. 3. Put tooling (A) in position on drive gear (4). Loosen drive gear (4) from the magneto drive sleeve. Remove tooling (A). 4. Disconnect oil supply line (7) from magneto drive (6).5. Remove nuts (5) and washers that hold magneto drive (6) in place. Remove magneto drive.Install Magneto Drive
1. Put magneto drive (1) in position on the front housing plate. 2. Install washers and nuts (2) that hold magneto drive in place.3. Connect oil supply line (3) to the magneto drive. 4. Install washer and bolt (4). Tighten bolt (4) to a torque of 110 5 lb.ft. (149 7 N m).5. Install gasket and cover (5) on the front housing. Tighten the nuts that hold the cover in place to a torque of 20 5 lb.ft. (25 7 N m).end by:a) install service meterb) install magnetoDisassemble Magneto Drive
start by:a) remove magneto drive 1. Remove O-ring seal (1) and bolt (2) from magneto drive (3). 2. Turn magneto drive (3) over and remove magneto drive gear assembly (5).3. Remove adapter assembly (4) and gasket from housing (6). 4. Use a hammer and punch and remove taper pin (7) from magneto drive gear assembly (5). 5. Put magneto drive gear assembly (5) and tooling (B) in position in a press as shown.6. Use tooling (A) and press to push shaft (8) from gear (9).7. Remove key from shaft (8). 8. Inspect bushing (11) for wear and damage. If a replacement is necessary, bushing (11) must be destroyed to be removed.9. Inspect seal (10) for wear and damage. If a replacement is necessary, seal (10) must be destroyed to be removed. 10. Turn adapter assembly (4) over. Inspect bearing (12) for wear and damage. If a replacement is necessary, bearing (12) must be destroyed to be removed. 11. Remove idler gear (13) from housing (6). 12. Inspect bearing (14) for wear and damage. Use tooling (A) to remove if necessary. 13. Put housing (6) in position on a press.14. Install a 1/2"-20 NF x 2" bolt (15) in shaft assembly as shown.
Make sure gear on shaft assembly (17) does not make contact with the press while the shaft assembly is pushed from sleeve (16).
15. Use press to push shaft assembly (17) free of sleeve (16).16. Remove shaft assembly (17), bolt (15) and sleeve (16) from housing (6). 17. Inspect bearings (18) and (19) for wear and damage. If a replacement is necessary, bearings (18) and (19) must be destroyed to remove.Assemble Magneto Drive
Make an alignment of oil holes in bearings (1) and (2) with the oil holes in housing (3).1. If bearing (1) was removed, use tooling (A) to install the bearing even with the face of the housing.2. If bearing (2) was removed, use tooling (A) to install the bearing to the bottom of the bearing bore. 3. Put shaft assembly (5) into position in housing (3). Put tool (B) under gear of shaft assembly (5) for support. A new sleeve must be used each time sleeve (4) is removed.4. Use a press to install a new sleeve (4) on shaft assembly (5) as shown. 5. If bearing (6) was removed, use tooling (A) to install bearing even with face of gear (7). 6. Put gear (7) in position over shaft (8) in housing (3). 7. If seal (9) was removed, use tooling (A) to install seal to the bottom of the seal bore with the lip of the seal toward the inside. Put a small amount of engine oil on the seal lip.8. If bushing (10) was removed, use tooling (A) to install the bushing to the bottom of the bushing bore. 9. If bearing (11) was removed from adapter (12), use tooling (A) to install bearing even with the face of the adapter. 10. Install key on shaft (13).11. Use a press and tooling (C) to push gear (14) on shaft (13) until the holes in the gear and shaft are in alignment. 12. Install taper pin (15) that holds gear (14) in place. Move the metal (peen) on the small diameter end of taper pin (15) to hold the taper pin in place. 13. Install a new gasket and adapter (12) on housing (3).14. Put shaft (13) and gear into position in adapter. 15. Install O-ring seal (16) on housing (3). Put a small amount of engine oil on the O-ring seal.end by:a) install magneto drive