21506990 Volvo.Penta Charge air pipe

1. Remove bolts (1) and (4) to remove water line (2) from the engine.2. Remove tube assemblies (3) from the engine. 3. Remove bolts (6) to remove crankcase breather (5) and elbow (7) as a unit from the drive housing.4. Remove bolts (8) and remove cover (9) from the drive housing. 5. Remove bolts (10) from shafts (11) and use tooling (A) to remove shafts (11) and gears (12) from the drive housing. 6. If necessary, remove bearings (13) from gears (12). 7. Remove washer assemblies (14) from the drive housing. 8. Fasten a hoist to support (15) with tooling (B). Remove bolts (17) to remove support (15) and support assembly (16) as a unit from the drive housing. The weight of the supports is 102 kg (225 lb.). 9. Remove bolts (18) and remove governor control lever (19) from the injector control shaft.10. Drain the oil from the oil pan.11. Remove all the bolts that hold the oil pan to the engine. Install two 3/8"-16 NC guide bolts in each side of the oil pan. Fasten a hoist to the engine and lift the engine approximately 12 mm (0.5 in.) off of the oil pan. Put two 50 mm wide x 100 mm long x 6 mm thick (2" wide x 4" long x 1/4" thick) plates in position between the cylinder block and the oil pan on each side of the engine. Lower the engine on the plates and remove the hoist. The weight of the 3512 Engine is approximately 5902 kg (13,000 lb.) and the 3508 Engine is approximately 4445 kg (9800 lb.).
Fuel control linkage (21) must be moved for clearance to pull the front drive housing from the engine or damage to parts can be the result.
12. Fasten a hoist to front drive housing (20) with tooling (B). Remove all the bolts that hold the drive housing to the cylinder block and install two 5/8"-11 NC guide bolts. Remove front drive housing (20) from the engine. The weight of the drive housing is 209 kg (460 lb.).Install Front Drive Housing
1. Fasten a hoist to front drive housing (1) with tooling (A). Install two 5/8"-11 NC guide bolts in the end of the cylinder block. Put the gasket and housing in position on the guide bolts. Install the bolts and tighten all evenly. Remove the guide bolts. Install the remainder of the bolts. Cut the gasket even with the bottom of the drive housing.2. Fasten a hoist to the engine and lift the engine enough to remove the plates between the cylinder block and the oil pan. If the oil pan gasket is damaged, the engine will have to be removed from the oil pan to make a replacement of the gasket. Lower the engine on the oil pan and remove the guide bolts from the oil pan. Install all the bolts that hold the oil pan in position. 3. Install governor control lever (2) and the bolts that hold it to the injector control shaft. 4. Install a hoist to support (3) with tooling (A). Put support (3) and support assembly (4) as a unit in position on the drive housing and install the bolts that hold the supports in position. 5. Install washer assemblies (5) in the drive housing. 6. Use tooling (B) and a press to install the bearings in gears (6). Check the bore in the bearings after assembly. The bore in bearings must be 90.00 0.06 mm (3.543 .002 in.). 7. Install O-ring seals on shafts (7) and put clean engine oil on the seals. Put gears (8) in position and install shafts (7) in the drive housing.8. Put clean engine oil on the O-ring seal and install cover (11) in the drive housing. 9. Put a gasket and elbow (10) with crankcase breathers (9) in position and install the bolts to hold these in position. 10. Install tube assemblies (12) and water line (13) on the engine.11. Fill the engine with oil to the correct level.end by:a) install oil and water pump driveb) install accessory drive (front)c) install vibration damperd) install oil filter housinge) install crankshaft front seal and wear sleeve