861671 Volvo.Penta Repair kit

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     1P-2322     Combination Puller     1    
9S-9153 Puller Jaws     2    Start By:
Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove".Note: In this removal procedure, the crankshaft gear is removed from the engine.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g00541470
Note: Rotate the crankshaft until the timing marks on the crankshaft gear, the camshaft gear, the fuel injection pump gear and the oil pump gear are aligned.
Use Tool (A) and remove crankshaft gear (1) .
Check the key on the crankshaft. If the key is damaged, use a new part for replacement.Installation Procedure 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Always wear protective gloves when handling parts that have been heated.
Use an oven and heat the crankshaft gear to a temperature of 150 °C (302 °F).
Wear eye protection in order to prevent possible personal injury while performing the following steps.
Note: Ensure that the marks on the timing gears are in alignment. Align the fuel injection drive gear with the "33" mark with the "3" mark on the idler gear. Make an alignment of the "2" mark on the camshaft gear with the "22" mark on the idler gear. Align the "1" mark on the crankshaft gear with the "11" mark on the idler gear. The No. 1 cylinder is at the top center position when these marks are in alignment.
Install the crankshaft gear on the end of the crankshaft. Tap lightly with a rubber mallet or a brass hammer until the crankshaft gear is seated. Ensure that the crankshaft gear is seated against the shoulder on the crankshaft.Note: Ensure that the timing marks of the crankshaft gear are on the front.End By: Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install".Removal Procedure 2
Table 2
Required Tools    
Tool    Part Number    Part Description    Qty    
A     1P-0820     Hydraulic Puller     1    
9U-6600 Hand Hydraulic Pump     1    
0S-2398 Step Plate     1    
3H-0465 Push Puller Plates     4    
8B-7549 Puller Leg     2    
1B-4207 Full Nut     2    
8B-7551 Bearing Puller     1    Start By:
Remove the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Remove".Note: In this removal procedure, the crankshaft gear is removed after the crankshaft is removed from the engine. The weight of the crankshaft is 39 kg (86 lb).
Illustration 2 g00541880
Use Tool (A) to remove crankshaft gear (1) from crankshaft (2) .Note: Do not remove the crankshaft by tapping with a hammer.Note: Be careful not to damage the finished surfaces on the crankshaft.
Check the key on the crankshaft. If the key is damaged, use a new part for replacement.Installation Procedure 2
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Always wear protective gloves when handling parts that have been heated.
Use an oven and heat the crankshaft gear to a temperature of 150 °C (302 °F).