420561 Volvo.Penta Extension part

Start By:a. remove oil panb. remove vibration damperc. remove fan 1. Install Tooling (A) on the bottom of the cylinder block as shown. 2. Put Tooling (B) in position under Tooling (A) as shown. 3. Remove bolts (2) and vibration damper adapter (1) from the crankshaft.4. Loosen the clamps and remove the two hoses (3) and elbow that connect the water pump and radiator. 5. Remove bolts (4) that hold the engine front support to the frame. 6. Use Tooling (B) to lift the front of the engine approximately 25.4 mm (1 in.).Install Tool (C) in Tooling (B) and lower the weight of the engine on Tooling (B).7. Remove two upper bolts (5) and install Tooling (D). Remove the remainder of bolts (5). 8. Fasten a hoist to front support (6) and move it off Tooling (D). Remove front support (6) from the machine. The weight of front support (6) is 41 kg (90 lb.). 9. Remove Tooling (D) and bolts (7) to remove trunnion (8) from the timing gear cover. The D10R has two transmission cooler mounting bracket which connects to trunnion with the two lower trunnion mounting bolts. These brackets must be removed from the transmission cooler before removing the trunnion. 10. Inspect resilient mount (9) which is part of trunnion (8).11. Remove resilient mount (9) from the adapter if it is worn or damaged. The following steps are for the installation of the engine front support and trunnion. 12. Be sure the surface for resilient mount (9) on adapter (10) is clean and free of nicks or burrs.13. Put adapter (10) in a hydraulic press so the adapter will be evenly supported when resilient mount (9) is pressed in place.14. Place resilient mount (9) on adapter (10) so the vertical centers are aligned. Dimension (X) must be 105.92 mm (4.170 in.).Recheck this alignment because incorrect alignment will result in resilient mount damage.
Use Tooling (E) to press only against steel ring (11) of the resilient mount. Do not press against any other part of the resilient mount because damage to the resilient mount will occur.
15. Place Tool (E) on steel ring (11), and use a hydraulic press to install resilient mount (9) on adapter (10). Install resilient mount (9) to dimension (Y). Dimension (Y) must be 25.4 mm to 28.4 mm (1.00 to 1.12 in.).16. Put trunnion (8) in position and install bolts (7) to hold it to the timing gear cover. Tighten bolts (7) to a torque of 135 15 N.m (100 10 lb.ft.). Install the transmission oil cooler mounting brackets on D10R models.17. Install Tooling (D) in the trunnion. Fasten a hoist and put front support (6) in position on Tooling (D). Remove the hoist.18. Install two bolts (5) to hold front support (6). Remove Tooling (D) and install the remainder of the bolts to hold front support (6). Tighten bolts (5) to a torque of 205 27 N.m (150 20 lb.ft.).19. Use Tooling (B) to lift the front of the engine until Tool (C) can be removed from Tooling (B). Lower the front of the engine with Tooling (B) until the front support is in contact with the frame. Install the washers and bolts (4). Tighten bolts (4) to a torque of 570 80 N.m (420 60 lb.ft.).20. Install adapter (1) on the end of the crankshaft with bolts (2). Tighten bolts (2) to a torque of 200 25 N.m (150 18 lb.ft.).21. Install the two hoses (3) and elbow to connect the water pump to the radiator.End By:a. install fanb. install vibration damperc. install oil pan