3849960 Volvo.Penta Sleeve

start by:a) remove air starter Make sure there is a complete set of new gaskets, vanes, seals and O-ring seals before the air starter is disassembled. 1. Remove elbow (1) from cover assembly (2). 2. Remove silencer group (4) from motor housings (3). 3. Make marks to show the position of motor housing (3) in relation to gear case (7) for assembly purposes. Remove bolts (4) to remove gear case (7) and drive housing (6) as a unit from motor housing (3). 4. Use tool (A) to remove ring (9) from drive gear (8). This air starter is a right hand model and bolt (10) has left hand threads. The bolt for a left hand model starter has right hand threads. 5. Remove bolt (10) and washer (11) to remove drive pinion (12), a sleeve and spring from the end of the drive shaft.6. Make marks to show the position of drive housing (6) in relation to gear case (7) for assembly purposes. Remove bolts (13) and remove drive housing (6) from gear case (7). 7. Remove O-ring seal (14) from drive housing (6).
The drive shaft assembly, the piston and drive gear are under a spring force.
8. Install tooling (B) between drive gear (8) and piston (15). Use a press to make a compression of the piston return spring and remove the ring that holds the drive shaft assembly and piston in the drive housing. 9. Slowly release the press to remove the force of piston return spring (17). Remove tooling (B) from between the drive gear and piston and remove ring (16) from the piston. Remove the drive gear, the piston and drive shaft assembly as a unit from the drive housing. Remove piston return spring (17) from the drive housing. 10. Use a 5/16" hex wrench to loosen the drive gear bolt until the threads are free and remove drive shaft assembly (18) and piston (15) as a unit from drive gear (8). 11. Remove bulkhead (19) from piston (15). 12. Remove O-ring seals (20) from bulkhead (19). 13. Remove ring (21) from piston (15) and remove the piston from drive shaft assembly (18). Later model air starters will not have bumper (23).14. Remove O-ring seal (24), bumper (23) and seal (22) from piston (15). 15. Remove ring (33), cup (32), spring (31), driven clutch jaw (30), driving clutch jaw (29), bearing (28), washer (27), lockwasher (26) and bolt (25) from drive shaft assembly (18). Any time ring (34) is removed a replacement must be made. 16. Remove ring (34) to remove bearing (35) from drive shaft (18). 17. Use tool (C) to remove ring (37) and remove bearing (36) from gear case (7). Later model air starters will not have bumper (38) and backup ring (39). 18. Remove bumper (38) from drive housing (6).19. Remove backup ring (39) from drive housing (6). 20. Remove seat (40) and bearing (41) from drive housing (6). 21. Remove seal (42) from drive housing (6). 22. Make marks to show the position of cover assembly (2) in relation to motor housing (3) for assembly purposes. Remove cover assembly (2) and an O-ring seal from motor housing (3). 23. Remove bolt (44) to remove rotor pinion (43) from rotor shaft. 24. Loosen setscrew (46) and remove nut (45) from the rotor shaft.25. Remove bearing (47) from end plate (48). 26. Remove O-ring seal (49) and end plate (48) from the end of the rotor. 27. Remove vanes (50) from rotor (51). 28. Remove rotor (51) from motor housing (3). 29. Use a press to remove bearing (52) and end plates (53) from rotor (51). 30. Remove bearing (52) from end plate (53). 31. Remove washers (54) from end plate (53). 32. Remove O-ring seals (55) from cylinder (56). 33. Remove cylinder (56) from motor housing (3). Remove the remainder of the O-ring seals from the cylinder.Assemble Air Starter
Clean all parts thoroughly. Put 2S3230 Bearing Lubricant on all bearings and the drive assembly. Put a thin layer of SAE 10W oil on all other parts before assembly. 1. Install O-ring seals (1) on cylinder (2) and install the cylinder in housing (3). Make sure pin (5) is in alignment with opening (slot) (4) in housing (3). 2. Install O-ring seals (6) on cylinder (2). 3. Install end plate (7) on rotor (8). 4. Install O-ring seal (9) on the rotor shaft. 5. Install bearing (10) over the rotor shaft and in the end plate. 6. Install nut (11) on the rotor shaft with the shoulder toward the bearing. 7. Tighten the nut until there is .02 mm to .07 mm (.001 in. to .003 in.) clearance between the end plate and the rotor. Use a feeler gauge to check the clearance. Tighten bolt (12) and check the clearance again. Step 8 is for right hand rotation starters only. For the left hand rotation starters, the rotor is installed with the pinion end of the rotor away from the cylinder alignment pin. 8. Install rotor (8) in motor housing (3) with the pinion end of the rotor toward the cylinder alignment pin. Make sure pin (13) is in alignment with the hole in the end plate. 9. Install vanes (14) in the rotor. 10. Install end plate (15) on the rotor and make sure hole (16) in the end plate is in alignment with pin (17). 11. Install washers (18) in the end plate. 12. Put bearing (19) in position on the end plate. 13. Use tooling (B) and a press to install bearing (19) on the rotor shaft and in the end plate. 14. Install rotor pinion (20) and the bolt that holds it to the rotor shaft. Tighten the bolt to a torque of 120 N m (90 lb.ft.). 15. Install O-ring seal (22) around the rotor bearing and put cover assembly (21) in position on motor housing. 16. Put bearing (25) and ring (23) in position on drive shaft (24).