21269896 Volvo.Penta Cover

Table 1
Required Tools
Tool Part Number Part Description Qty
A 238-9586 Camshaft Drive Group 1
B 138-7573 Link Bracket 2
C - Guide Stud
1 - 14 by 6 inch 2
D 1U-7600 Slide Hammer Puller Gp 1
E 1U-7325 Distorter Adapter 1
F 5P-7409 Sleeve Distorter 1
G 8B-7548 Push-Puller Tool Group 1
8B-7559 Adapter 2
8B-7561 Step Plate 1
1P-0820 Hydraulic Puller 1
5H-1504 Hard Washer 3
9U-6600 Hand Hydraulic Pump 1
H 138-7573 Link Bracket 2
J - Guide Stud
5/8 - 11 by 6 inch 2
K 169-5464 Quick Cure Primer - Start By:
Remove the starting motor. Refer to Disassembly and Assembly, "Air Starting Motor - Remove". Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install".
If the exhaust elbow is attached to the flywheel housing, remove the exhaust elbow and remove the bracket for the exhaust elbow. Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install".
Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove".
Remove the engine speed sensor. Refer to Disassembly and Assembly, "Engine Speed Sensor - Remove and Install".
Remove the engine speed/timing sensor. Refer to Disassembly and Assembly, "Engine Speed/Timing Sensor - Remove and Install".
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01126909
Remove rear camshaft covers (1).
Remove timing pin (2) from the storage position.
Remove timing bolt (5) from the storage position. Remove cover (3) and plug (4) from the flywheel housing.
Use Tooling (A) to turn the flywheel in order to install timing bolt (5) in the flywheel and timing pin (2) in both camshafts. Refer to Testing and Adjusting, "Camshaft Timing". Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston".
Remove the timing bolt from the flywheel.
Illustration 2 g01126908
Remove tube (6).
Remove drain tubes (7) for the turbochargers. Remove the gaskets from the elbows.
Remove covers (8) and the gasket.
Illustration 3 g01139900
Install Tooling (B) and a suitable lifting device on flywheel (9). The weight of flywheel (9) is approximately 170 kg (375 lb).
Remove two bolts (10) and install Tooling (C).
Remove remaining bolts (10). Remove flywheel (9).
Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine.
Illustration 4 g01139914
Use Tooling (D) or a punch and hammer in order to puncture three or more holes in crankshaft rear seal (11).
Use Tooling (D) to remove crankshaft rear seal (11).
Illustration 5 g01139915
Insert Tooling (E) between the flywheel housing and wear sleeve (12).
The use of excessive force on the sleeve distorter can cause the distorter adapter to crack the housing. To help avoid damage to the engine, do not use excessive force to remove the wear sleeve.
Insert Tooling (F) between Tooling (E) and wear sleeve (12). Carefully turn Tooling (F) until the edge of the tool causes a crease in wear sleeve (12). Repeat this procedure several times