881684 Volvo.Penta Starter motor

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0510 Driver Group 1
B 9S-3263 Thread Lock Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Check the condition of the gaskets and the O-ring seals. If the gaskets or the O-ring seals are worn or damaged, use new parts for replacement.
Clean the old gasket from the contact surfaces of the timing gear plate and the cylinder block. Install a new gasket on the cylinder block. Cut the gasket even with the bottom face of the cylinder block.
Illustration 1 g00476419
The bolts that hold the timing gear plate in position on the cylinder block should have a reduced bolt head thickness. The reduced bolt head thickness is needed for clearance for the gears.
Ensure that the O-ring seals are in position on the end of the fuel injection pump housing. Put timing gear plate (9) in position on the cylinder block. Install bolts (10).
Illustration 2 g00476418
Install shield (7). Install nuts (8). Note: After the timing gear plate is installed, ensure that the rack is free to move in the fuel injection pump housing. The O-ring seal on the drive end of the fuel injection pump housing can hold the rack. This can help prevent free rack movement. Rack movement can be seen through a hole in the timing gear plate just above the mounting of the fuel pump gear. If the rack does not move freely, remove the timing gear plate and check the O-ring seal on the drive end of the fuel injection pump housing.
If the rack does not move freely, the engine can over speed and be damaged. Serious personal injury may result.
Illustration 3 g01072912Note: If idler gear shaft (11) for the fuel pump idler gear was removed, use Tooling (B) on the threads of bolts (12) and nut (13) before reinstalling idler gear shaft (11). Tighten bolts (12) and nut (13) to a torque of 50 10 N m (37 7 lb ft).
Put camshaft gear (6) and plate (5) in position on the engine. Align the Mark “C” on the camshaft gear with the Mark “C” on the crankshaft gear. Install bolts (4) and tighten bolts (4) to a torque of 55 7 N m (41 5 lb ft).
Illustration 4 g00476416
Use Tooling (A) in order to install the bearing in fuel pump idler gear (3). The end of the bearing must be 3.00 0.25 mm (.118 .010 inch) below the face of the hub of the fuel pump idler gear.
Illustration 5 g00476414
Ensure that the oil hole in the shaft for fuel pump idler gear (3) is open. Install fuel pump idler gear (3). Put plate (2) in position with the finished side facing toward fuel pump idler gear (3). Apply Tooling (B) on bolts (1). Install bolts (1) that hold fuel pump idler gear (3) in position. Note: Remove excess Tooling (B) on plate (2). Excess Tooling (B) on plate (2) may flow into the gear bearings. This condition can affect lubrication. Bearing life can also be affected.End By:
Install the automatic timing advance unit. Refer to Disassembly and Assembly, "Automatic Timing Advance - Install".