978515 Volvo.Penta V-belt

1. Remove bolt (2) and washer from the fuel injection pump.
Hold puller with hand to prevent injury when gear (1) is removed from the shaft.
2. Install tooling (A) on gear (1). Remove gear from the fuel injection pump. Before any timing gears are removed, make sure "C" mark on the crankshaft gear is in alignment with "C" mark on the camshaft gear.3. Remove bolts (3) and the plate. Remove idler gear (2). Remove bolts (4) and gear (5) from camshaft. 4. Remove the bearing from the idler gear (2) with tooling (B) and a press. 5. Remove the three nuts and washers that hold the fuel injection pump housing to the back of the timing gear plate (6).6. Remove the six bolts (7) and the locks that hold the timing gear plate to the cylinder block. Remove the timing gear plate and gasket from the cylinder block.7. Remove the O-ring seal from the fuel pump housing.Install Timing Gears And Plate
1. Make sure O-ring seal (1) is in place on the fuel housing pump.2. Clean the old gasket from the contact surfaces of the timing gear plate and cylinder block. Install a new gasket on the cylinder block. Cut the gasket even with the bottom face of the cylinder block. Put 5H2471 Gasket Cement on the bottom of the gasket where the gasket makes contact with the gasket for the oil pan plate. 3. Put timing gear plate (3) in position on the cylinder block and install the locks and bolts that hold it in place. Install the three nuts that hold the fuel injection pump housing to the back of the timing gear plates.
After the timing gear plate is installed, be sure 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 and prevent free rack movement. Rack movement can be seen through hole (2) in the timing gear plate. 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 overspeed and be damaged. Serious personal injury can be the result.
4. Install the camshaft gear with the "C" marks on both the camshaft and crankshaft gears in alignment. Install the bolts that hold the gear on the camshaft and tighten them to a torque of 55 7 N m (41/8 5 lb.ft.). 5. Use tooling (A) and a press to install the bearing in idler gear (6). The end of the bearing must be .060 in. (1.52 mm) below the face of the gear hub. 6. Be sure the oil hole (6) is open. Install idler gear (6) on the shaft. Put the plate in position with the finished side toward gear (6) and install the bolts that hold the plate and gear (6) on the shaft. 7. Put fuel injection pump drive gear (7) in position on the fuel injection pump camshaft. Install the washer and bolt that hold the gear in place but do not tighten. The flat side of the washer must be away from the gear. For correct installation of the fuel injection pump drive gear and timing of the engine, see INSTALL FUEL INJECTION PUMP HOUSING AND GOVERNOR.END BY:a) install timing gear cover