826409 Volvo.Penta Cover

Table 1
Required Tools
Tool Part Number Part Description Qty
A 9U-6600 Hand Hydraulic Pump 1
8B-7548 Push-Puller Tool Group 1
8B-7559 Adapter 2
1P-0820 Hydraulic Puller 1
5H-1504 Hard Washer 3
B 138-7573 Link Bracket 2
C 169-5464 Quick Cure Primer - Start By:
Remove the starting motors. Refer to Disassembly and Assembly, "Air Starting Motor - Remove" or Disassembly and Assembly, "Electric Starting Motor - Remove and Install".
Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove".
Remove the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove".
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Remove the engine speed/timing sensor. Refer to Testing and Adjusting, "Engine Speed/Timing Sensor".
Use the timing pins in order to properly time the engine. Refer to Testing and Adjusting, "Camshaft Timing". Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston".
Illustration 1 g00588653
Typical example
Remove camshaft covers (1) and the gaskets from flywheel housing (2).
Remove the crankshaft rear seal and the wear sleeve. Refer to Disassembly and Assembly, "Crankshaft Rear Seal and Wear Sleeve - Remove".
Illustration 2 g00588654
Remove the bolt and timing ring (3).
Illustration 3 g00588655
Remove the bolt and plate (5) from camshaft drive gear (4).
Illustration 4 g00588656
Place the three washers of Tooling (A) behind plate (5) and install the bolt and plate (5).
Do not apply more than 51675 kPa (7500 psi) pressure to the hydraulic puller. The adapters are rated at 6 1/2 tons each and the hydraulic puller is rated at 17 tons at 68900 kPa (10000 psi). If too much pressure is applied, the gear may be damaged.
Install Tooling (A) on camshaft drive gear (4). Apply 51675 kPa (7500 psi) to the puller. Use a hammer to tap the head of the puller screw on Tooling (A). This will break camshaft drive gear (4) free from the camshaft.
Repeat the procedure for the remaining camshaft drive gear.
Place blocks under the engine. The engines have the following weights.
The weight of the G3508 Engines are approximately 4300 kg (9500 lb).
The weight of the G3512 Engines are approximately 5443 kg (12000 lb).
The weight of the G3516 Engines are approximately 6447 kg (14200 lb).
Illustration 5 g00588658
Typical example
Install Tooling (B) and a suitable lifting device on the top of flywheel housing (2). The weight of flywheel housing (2) is approximately 210 kg (460 lb).
Remove all bolts from flywheel housing (2). Note: Dowel pins are used for the alignment of the flywheel housing on the engine block.
Remove flywheel housing (2) from the engine.
After removing flywheel housing (2), clean the mating surface of the cylinder block and the mating surface of the flywheel housing with Tooling (C). If necessary, use a gasket scraper and a solvent in order to remove any residual gasket material. Both mating surfaces must be clean, dry, and free of any oil before installation.