3851590 Volvo.Penta Gasket

The Engine Overhaul In Chassis was done on a Kenworth Model 900 truck with a Caterpillar 3406 Engine. Put identification on all parts that are removed for correct installation.
Do not let steam get into air inlet, air outlet or alternator.
1. Steam clean the complete engine. 2. Remove wing nuts (2) and battery cover (1) from the left side of the truck.
Do not smoke when a check is made of electrolyte level. Batteries give off flamable fumes. Do not permit electrolyte solution to make contact with skin or eyes. Electrolyte solution is an acid. Fasten ground cable last, and remove first to prevent sparks near the battery, which can cause battery vapors to burn with much force (explode).
3. Disconnect battery cables (3), (4), (5) and (6). 4. Remove plug (7) and drain the coolant from the radiator and cylinder block. 5. Remove two bolts (9) and cover (8) from the left side of the oil pan. 6. Remove drain plug (10) and drain the oil from the oil pan. 7. Use tool (A) and remove oil filter (11). 8. Remove bolts (12) that hold the oil pan in place. Remove oil pan (13) from the cylinder block. 9. Remove suction bell (15) and suction bell tube (14) from the oil pump. 10. Remove oil supply tube (16). 11. Remove the three bolts that hold the oil pump to the cylinder block. Remove oil pump (17).12. Check the connecting rods and caps for their identification and location. Inspect bearings for damage as the caps are removed. See REUSABILITY GUIDELINES, Form No. SEBF8008, MAIN AND CONNECTING ROD BEARINGS. 13. Turn the crankshaft until two connecting rod caps are at bottom as shown. Remove four nuts (18) and two rod caps (19).14. Install the rod caps in their original position. Install the nuts but do not tighten.15. Do Steps 12 through 14 for the remainder of the connecting rods. 16. Remove Nos. 2, 3, 4, 5 and 6 main bearing caps. Inspect the bearings.17. Install Nos. 2 and 6 main bearing caps and remove Nos. 1 and 7 main bearing caps. Inspect the bearings.18. Inspect the crankshaft journals for damage and wear. If the crankshaft is not damaged, go to the next step. If the crankshaft is to be ground (a new surface put on) or a replacement is needed, remove the engine from the chassis. 19. Loosen clamp on air inlet piping and remove bolts (20). Remove air cleaner and air inlet piping as a unit. 20. Loosen clamp (22) and remove air inlet piping (21) as a unit. 21. Use tool (A) and remove fuel filter (23) from the fuel filter base. Put plugs or caps on all openings. 22. Disconnect fuel lines (24), (25) and (26) from the fuel block. 23. Remove two bolts (27) and remove fuel priming pump (28) from the fuel filter base. 24. Disconnect fuel line (29) from the fuel filter base. 25. Disconnect line (30) from the inlet manifold. 26. Remove wire and brackets (32) and (34) from inlet manifold. Disconnect brackets (31) and (33) from the inlet manifold. 27. Disconnect line (37) from the starting aid. Remove two nuts (36) and push starting aid (35) clear of the bracket. 28. Disconnect tachometer drive cable (38) from the tachometer drive. 29. Remove twelve bolts (42) that hold inlet manifold (40) to the cylinder head. Remove inlet manifold (40), turbocharger tube (39) and elbow (41) as a unit. 30. Disconnect outer fuel injection lines (43) from the cylinder head. Put plugs in the fuel injection lines to keep dirt out.31. Disconnect air compressor water line (44) from the air compressor. 32. Remove clamp (45) and disconnect the exhaust piping from the turbocharger. 33. Remove two bolts (46) that hold the oil supply tube to the turbocharger. Disconnect oil supply tube (47) from the oil filter base. Remove the oil supply tube. It is not necessary to remove oil drain tube (48) at this time.34. Remove two bolts (49) that hold oil drain tube (48) to the turbocharger. 35. Loosen adjusting nut (50) for the alternator. Disconnect wires (51) from the alternator. 36. Remove bolts (52), (54) and (55) that hold alternator (53) in place. Remove alternator (53). 37. Disconnect wires (58).38. Loosen clamps (56) and (59) for the upper radiator hose. Remove upper radiator hose (57). 39. Disconnect water vent line (62) from the fitting.
Do not disconnect any of the refrigerant lines connected to the air conditioning compressor.
40. Remove four bolts (61) and (63) and push air conditioning compressor (60) clear of the engine. 41. Remove bolts (64) that hold the elbow to the water temperature regulator housing. Remove elbow (65) from the water pump. 42. Remove three bolts (66), water temperature regulator and water temperature regulator housing (67). 43. Disconnect hoses (68) and (69) from the water pump.44. Disconnect lower radiator hose (70) from the water pump. 45. Disconnect oil temperature gauge wire (73) from the oil temperature sensing unit. Remove oil temperature sensing unit (74) from the cylinder block.46. Remove bolts (72) and remove cover (71) from the back of the water pump. 47. Remove two bolts (75) that hold oil cooler bonnet (76) to the water pump. 48. Remove bolts (77) that hold cover (79) and water pump (78) to the timing gear cover. Remove water pump (78) from the timing gear cover. 49. Remove clamp (82). Remove the two clamps that hold tube (81) in place. Remove breather (80) and breather tube (81) as a unit. 50.