3803077 Volvo.Penta Starter motor, exch

Table 1
Required Tools
Tool Part Number Part Description Qty
A 241-4232 Alignment Tool 1
B - Multipurpose Grease 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
If the front housing is not installed, do not turn the crankshaft. Damage to the engine may occur.
If the idler hub for the engine oil pump was removed from the cylinder block, the engine oil pump must be replaced as an assembly.
If the idler hub for the engine oil pump was not removed from the cylinder block. Ensure that all components of the engine oil pump are free from wear and damage. If any component is not free from wear or damage, the engine oil pump should be replaced as an assembly.
Illustration 1 g06276005
Illustration 2 g06475043
Typical example
Install the pin of Tooling (A) to the cylinder block.
Install a suitable 6 mm (0.236 inch) washer (11) to the recess of Tooling (A).Note: The installation of a suitable washer to the recess of Tooling (A) will compensate for the thickness of the back plate.
Install idler hub (1) into the Tooling (A). Align Tooling (A) with pin of Tooling (A).
Use a soft face hammer to drift Tooling (A) and drive idler hub (1) fully into the cylinder block.
Remove Tooling (A) and spacer (11).
Install bolts (10). Tighten the bolts to a torque of 10 N m (89 lb in).
Illustration 3 g06475034
Illustration 4 g06475038
Typical example
Lubricate thrust washer (2) with clean engine oil. Install the thrust washer.
Improper assembly of parts that are spring loaded can cause bodily injury.To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Apply Tooling (B) to the faces of inner rotor (4) and to the vanes of idler gear (3).
Align timing Marks (X) on idler gear (3) with the respective timing marks on camshaft gear (12) and crankshaft gear (13). Install the idler gear onto idler hub (1).
Install inner rotor (4) to idler gear (3).
Personal injury can result from the release of the spring force.The drive shaft, the piston, and the drive gear are under spring force.Use a press to slowly release the spring force before the components are removed.
Install the following items to idler hub (1):
Oil pump cover (5)
Shim (6)
Spring (7)
Collar (8)Refer to Illustration 7.
Install C-clip (9) to the shaft of idler hub (1).
Illustration 5 g01320625
Checking end play by using a feeler gauge
Use a feeler gauge to measure the end play of the engine oil pump. Refer to Specifications, "Engine Oil Pump" for further information.Method Two for Installation of Idler Hub
Table 2
Required Tools
Tool Part Number Part Description Qty
A 241-4232 Alignment Tool 1
B - Multipurpose Grease 1
If the idler hub for the engine oil pump was removed from the cylinder block, the engine oil pump must be replaced as an assembly.
If the idler hub for the engine oil pump was not removed from the cylinder block. Ensure that all components of the engine oil pump are free from wear and damage. If any component is not free from wear or damage, the engine oil pump should be replaced as an assembly.