11990043 Volvo.Penta Repair kit

Table 1
Required Tools
Tool Part Number Part Description Qty
A 230-6284 Timing Pin (Camshaft) 1
B 230-6283 Timing Pin (Crankshaft) 1
C 9U-7324 Indicator Bracket 1
7H-1942 Dial Indicator 1
3S-3268 Indicator Contact Point 1
7H-1940 Universal Attachment 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that number one piston is at the top center position on the compression stroke. Refer to the Systems Operation, Testing and Adjusting, "Finding Top Center Postion for No. 1 Piston".
Illustration 1 g01343975
Alignment of timing marks
Ensure that Tooling (A) is installed into hole (X) in camshaft gear (1).
Ensure that Tooling (B) is installed in hole (Y) in the front housing. Use Tooling (B) in order to lock the crankshaft in the correct position. Refer to Systems Operation, Testing and Adjusting, "Finding Top Centre Position for No.1 Piston".
Illustration 2 g01269934
Clean idler gear (2) and inspect the idler gear for wear or damage. Refer to Specifications, "Gear Group (Front)" for more information. If necessary, replace the idler gear.
Clean hub (7) and inspect the hub for wear or damage. Refer to Specifications, "Gear Group (Front)" for more information. If necessary, replace the hub.
Lubricate hub (7) with clean engine oil. Slide the hub into idler gear (2). Ensure that the timing marks are toward the front of the idler gear.
Illustration 3 g01269935
Typical example
Align the timing mark on idler gear (2) with the timing mark on the camshaft gear. Refer to the Illustration 1. Install the assembly of idler gear (2) and hub (7) 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 (3) and inspect the plate for wear or damage. If necessary, replace the plate.
Lubricate plate (3) with clean engine oil. A used plate should be installed in the original orientation. If a new plate is installed, ensure that the holes in plate (3) are aligned with the holes in hub (7). Install plate (3) to hub (7).
Install bolts (1). Tighten bolts (1) to a torque of 44 N m (32 lb ft).
Illustration 4 g01269936
Checking end play by using a set of feeler gauge's
Use a set of feeler gauge's in order to check the end play for the idler gear. Refer to Specifications, "Gear Group (Front)" for more information.
Use Tooling (C) in order to check the backlash between the idler gear and the camshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.
Use Tooling (C) in order to check the backlash between the idler gear and the crankshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.
Lightly lubricate all of the gears with clean engine oil. End By:
Install the fuel injection pump gear. Refer to Disassembly and Assembly, "Fuel Pump Gear - Install".
If the engine is equipped with an air compressor, install the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove and Install".
If the engine is equipped with a vacuum pump, install the vacuum pump. Refer to Disassembly and Assembly, "Vacuum Pump - Remove and Install".
If the engine is equipped with an accessory drive, install the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive - Remove and Install". Installation Procedure (Heavy-Duty Idler Gear)
Table 2
Required Tools
Tool Part Number Part Description Qty
A 230-6284 Timing Pin (Camshaft) 1
B 230-6283 Timing Pin (Crankshaft) 1
C 9U-7324 Indicator Bracket 1
7H-1942 Dial Indicator 1
3S-3268 Indicator Contact Point 1
7H-1940 Universal Attachment 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that number one piston is at the top center position on the compression st