966146 Volvo.Penta Plug

start by:a) remove front timing gear housingb) remove valve covers The engine is removed from the machine for the purpose of illustration. 1. Remove plate (1) from the left side of the flywheel housing. Bolt (2) is also the timing bolt for the flywheel. 2. Remove bolts (4) that hold pinion (3) and spacer (5) to the flywheel housing. 3. Install pinion (3) in the flywheel housing. Use a 1/2" ratchet to turn the engine.4. Turn the engine clockwise (as seen from the flywheel) approximately 30° to remove the play in the timing gears. Turn the engine counterclockwise (as seen from the flywheel) until the threaded hole in the flywheel is in alignment with the hole in the flywheel housing and bolt (2) can be installed in the flywheel. The No. 1 piston is at top center compression stroke.5. The intake and exhaust valve for the No. 1 cylinder on the right side of the engine must be free to move by hand. If not, it will be necessary to turn the engine counterclockwise (as seen from the flywheel) 360° more and install bolt (2) again. If the hole in the flywheel is turned beyond the hole in the flywheel housing, turn the engine clockwise as seen from the flywheel) a minimum of 30° before the engine is turned counterclockwise (as seen from the flywheel) to install bolt (2).6. Install the timing pin in the left intake camshaft. 7. Remove washer (6).8. Remove oil pump idler gear (7). 9. Use tooling (A) and a press to remove the bearing from oil pump idler gear (7). 10. Remove shaft (8) from the housing.11. Remove the O-ring seal (not shown) from the housing. 12. Remove washers (10) from the shaft. 13. Remove cluster gear (9).14. Remove the washer (not shown) from the shaft.15. Use tooling (A) and a press to remove the bearing from cluster gear (9). 16. Remove plate (11).17. Remove plate (12), water pump idler gear (13) and the washer (not shown) from the shaft. 18. Use tooling (A) and a press to remove the bearing from gear (13). 19. Remove the locks and the bolts that hold plate (14) in position. Remove plate (14). 20. Remove tube assembly (17) from the shaft and the cylinder block.21. Remove shaft (16) and idler gear (15). 22. Use tooling (B) and a press to remove the bearing from idler gear (15). 23. Remove crankshaft gear (16) from the crankshaft.Install Front Timing Gears And Plate
1. Clean and inspect all parts. Make a replacement of the parts that are worn or damaged.
Make sure the notch in the bearing is in alignment with the notch in the idler gear within 2°.
2. Use tooling (A) and a press and install the bearing in idler gear (1). Make sure the bearing does not extend beyond either face of the idler gear. The inside diameter of the bearing after assembly must be 3.2510 .0019 in. (82.575 0.048 mm). 3. Put idler gear (1) in position. Install shaft (2). Install the lock and bolts that hold shaft (2). 4. Install tube assembly (4).5. Make sure gasket (3) is in position on the engine. 6. Put crankshaft gear (6) in position on the crankshaft. Install the locks and bolts that hold it.7. Put plate (5) on the front. 8. Use tooling (B) and a press and install the bearing in water pump idler gear (7). Install the bearing to a depth of .050 in. (1.27 mm) below the outside surface. The inside diameter of the bearing after assembly must be 2.0022 .0012 in. (50.856 0.030 mm). 9. Put washer (8) in position on the shaft.10. Put water pump idler gear (7) in position on the shaft.11. Install plates (9) and (10). Install the locks and bolts. 12. Use tooling (B) and a press and install the bearing in cluster gear (11). Install the bearing to a depth of .060 in. (1.52 mm) below the outside surface. The inside diameter of the bearing after assembly must be 1.5065 .0019 in. (38.265 0.048 mm).
Always be sure that the No. 1 piston is at top center compression stroke, the timing bolt is installed in flywheel and timing pin is installed in timing opening in left inlet camshaft housing before installation of cluster gear. Do not turn the engine with the timing gears removed. Damage to the engine can be the result if the above procedure is not followed.
13. Put the washer in position on the shaft. 14. Put cluster gear (11) in position with the "V" mark on cluster gear (11) in alignment with the "V" mark on crankshaft gear (6).15. Put washer (12) in position on the shaft.
Make sure the notch in the bearing is in alignment with the notch in the oil pump idler gear within 4°.
16. Use tooling (A) and a press and install the bearing in oil pump idler gear (13). Install the bearing to a depth of .060 in. (1.52 mm) below the outside surface. The inside diameter of the bearing after assembly must be 1.5015 .0019 in. (38.138 0.048 mm). 17. Install the O-ring seal in the bore for shaft (14). Put clean oil on the shaft and install shaft (14). Install the locks and bolts that hold it. 18. Put oil pump idler gear (13) in position on shaft (14).19. Install washer (15), the locks and the bolts that hold it.20. Remove the timing pin from the inlet camshaft. Remove the bolt from flywheel. Install the timing pin and bolt in their storage positions.end by:a) install front timing gear housingb) install left valve cover