835548 Volvo.Penta Repair kit

Illustration 1 g00483155 (1) Camshaft drive gears
Illustration 2 g01042492 (2) Idler gears Backlash between the camshaft drive gears and the idler gears ... 0.160 to 0.795 mm (0.0063 to 0.0313 inch)Bore for bearing ... 150 0.02 mm (5.905 0.0008 inch) (A) Base diameter. ... 160 0.02 mm (6.299 0.0008 inch) (B) Depth of installed bearing in gear's bore ... 3.0 0.5 mm (0.118 0.02 inch) (C) Circular runout of the bearing bore established by the axis of the gear's base diameter. ... 0.13 mm (0.0051 inch) (D) Inner diameter of bearing bore after machining ... 150.002 .020 mm (5.9056 0.0008 inch) (E) Maximum roughness of machined bearing bore ... 0.8 micrometers (3) Small cluster idler gear Backlash between the idler gears and the small cluster idler gear ... 0.067 to 0.778 mm (0.0026 to 0.0306 inch) (4) Idler gear (5) Torque for the bolts that connect the idler gear to the small cluster idler gear ... 135 20 N m (100 15 lb ft) (6) Crankshaft gear Backlash between the idler gear and the crankshaft ... 0.216 to 0.949 mm (0.0085 to 0.0374 inch)
Illustration 3 g00483156 (7) Mounting bolts for the idler shafts Use the following procedure in order to tighten the mounting bolts for the idler shaft.
Illustration 4 g00483157
Use the following sequence in order to tighten and turn the bolts. Two idler shafts with 8 bolt patterns ... 1-5-3-7-2-6-4-8One idler shaft with 10 bolt pattern ... 1-6-3-8-5-10-7-2-9-4
Tighten the bolts. Torque ... 160 16 N m (120 12 lb ft)
Tighten each of the bolts for an additional 45 5 degrees. (8) Locking plate and bolts (9) Bolt that holds the camshaft drive gear in position Use the following procedure in order to install the camshaft drive gears:Note: Use the manual barring group to rotate the engine. The engine must be prelubed before rotating the crankshaft in order to perform service work. Rotating the crankshaft before prelube may cause damage to the crankshaft bearings if the mating surface is dry.
Rotate the engine to the Top Center position of the compression stroke for the number one cylinder. Install the crankshaft timing pin.
If the crankshaft timing pin location is missed, do not turn the flywheel in the opposite direction to install the crankshaft timing pin. If the crankshaft timing pin location is missed, repeat Step 1.
Install the camshaft timing pin.
Put the camshaft drive gear (1) in position on the camshaft. Install the plate and the bolt hand tight. Note: Make sure that the gear taper and the camshaft taper are clean and dry. Make sure that the gear taper and the camshaft taper are free of dirt, rust and lubricants.
To prevent the crankshaft from turning, engage the manual barring group. Tighten the locking guide. Torque ... 270 25 N m (200 18 lb ft)
Apply 4C-5591 Anti-Seize Compound to the threads and to the seating face of the bolt. Use a torque multiplier to tighten the camshaft bolt. Torque ... 2000 275 N m (1480 200 lb ft)
Strike the plate with a hammer in order to seat the gear taper on the camshaft. Repeat Step 5.
Repeat Step 6 until there is no change in the bolt torque.
Loosen the locking guide on the manual barring group. Verify the relation of the crankshaft to the camshaft by installing the timing pins. If both timing pins cannot be installed, loosen the bolt and the camshaft drive gear. Repeat the procedure for installing the camshaft drive gear. (10) Outside diameter of idler gear shaft ... 149.850 0.020 mm (5.8996 0.0008 inch) (11) Thickness of idler gear thrust washers ... 9.60 0.05 mm (0.378 0.002 inch) (12) Idler gear shaft Outside diameter of the shaft for the small cluster idler gear ... 105.860 0.020 mm (4.1677 0.0008 inch)
Illustration 5 g00483159 (13) Install the bearing in small cluster idler gear (3) to the following depth. ... 3.0 0.5 mm (0.12 0.02 inch) (14) Bearing for the small cluster idler gear Outside diameter of bearing for small cluster idler gear (3) ... 114.171 0.026 mm (4.4949 0.0010 inch)Bore in gear for bearing ... 114.000 0.020 mm (4.4882 0.0008 inch)
Illustration 6 g00483240 (15) Install the bearing in idler gear (2) to the following depth. ... 3.0 0.5 mm (0.12 0.02 inch) (16) Bearing for the idler gear Inside diameter of bearing for idler gear (2) ... 150.002 0.020 mm (5.9056 0.0008 inch)Bore in gear for bearing ... 160.000 0.020 mm (6.2992 0.0008 inch)