418265 Volvo.Penta Gasket

1. Remove two bolts (1) that hold bracket assembly (2) in position on the flywheel housing. 2. Remove the bolt that holds clip (3) in position on the cover for the oil filter bypass valve. Remove four bolts (4) and move bracket assembly (2) away from the flywheel housing. 3. Remove the bolt that holds brace (5) to the aftercooler. Remove the bolt that holds brace (6) to the flywheel housing. Loosen clamp (7). 4. Fasten tool (A) and a hoist to the top of the air cleaner housing.5. Remove four bolts (9) that hold air cleaner support (8) against the flywheel. Remove the air cleaner housing and support. The weight of the air cleaner housing and support is approximately 23 kg (50 lb.). 6. Disconnect oil line (11) from the cylinder block. Steps 7 through 11 are for engines that have watercooled exhaust manifolds and turbochargers.7. Drain the cooling system to a level below that of the exhaust manifold.8. Remove the nuts and bolts that hold exhaust elbow (10) in position against exhaust manifold (12).9. Remove the bolts that hold elbow (13) in position against elbow (10). 10. Disconnect water line (14) from the top of the turbocharger. Remove the bolts that hold elbows (15) to watercooled exhaust elbows.11. Remove the bolts that hold oil line (11) to the top of the turbocharger. Remove oil line (11). 12. On engines with hot manifolds, remove the nuts and bolts that hold clips (16) to shield (17). Remove the two bolts that hold oil line (11) to the top of the turbocharger. Remove oil line (11). 13. Remove the two bolts that hold oil line (18) to the bottom of the turbocharger. Steps 14 through 17 are for engines with watercooled exhaust manifolds and turbochargers.14. Disconnect water line (19) from the bottom of the turbocharger. 15. Remove the bolt that holds clip (21) in position against the elbow. Loosen the end of water line (19) from bonnet (24).16. Remove the three nuts and bolts that hold manifold (22) to exhaust manifold (20).17. Remove the two bolts that hold elbow (23) to manifold (22). 18. Remove shield (25) and clamp (26) from the exhaust manifold. 19. On the other side of the engine, remove clamp (27) and support (28). 20. Fasten two straps and a hoist to turbocharger (29) as shown. Remove the four nuts that hold the manifold and turbocharger to plate (30). Remove turbocharger (29) and the manifold from the engine as a unit. The weight of the turbocharger and manifold is approximately 72 kg (158 lb.).21. Remove plate (30) and adapter (31) from the flywheel housing. 22. Remove the bolts that hold the oil pan to the flywheel housing. Loosen the rest of the bolts that hold the oil pan in position.23. Install tooling (B) and a hoist to the flywheel housing as shown. 24. Use tooling (B) and a hoist to lift the end of the engine enough so a 1/2" hardened washer (32) can be installed on each side of the engine between the oil pan and the cylinder block.25. Remove the blocks from under the flywheel housing. Put a block under the oil pan to give support to the rear of the engine. Lower the rear of the engine down on to the block.
Typical Example Step 26 is for 3412 Generator sets only.26. Remove two covers (33) from the flywheel housing. 27. Remove the bolts that hold flywheel housing (34) in place. Remove flywheel housing (34). The weight of the flywheel housing is approximately 84 kg (186 lb.).Install Flywheel Housing
1. Install two 1/2"-13 NC × 4" long guide bolts in the cylinder block. Make sure gasket (2) is in position. The cylinder block, both sides of gasket (2) and the surface of the flywheel housing that makes contact with the gasket must not have any oil, fuel, water or gasket adhesive on them when the flywheel housing is installed on the engine.2. Install flywheel housing (1) on the engine. The weight of the flywheel housing is approximately 84 kg (186 lb.).
Torque Sequence3. Install the bolts that hold the flywheel housing in place.4. Use the following procedure to tighten the bolts:a) Tighten bolts 1 through 8 in number sequence to 136 14 N m (100 10 lb.ft.).b) Tighten bolts 9 through 20 in number sequence to 54 7 N m (40 5 lb.ft.).c) Again, tighten bolts 1 through 8 in number sequence to 136 14 N m (100 10 lb.ft.).d) Again, tighten bolts 9 through 20 in number sequence to 54 7 N m (40 5 lb.ft.). If a new gasket is installed, cut the ends of the gasket so it is even with the bottom of the cylinder block.
Typical Example Step 5 is for 3412 Generator Sets only.5. Install the gaskets and covers (3) on the flywheel housing. 6. Use tooling (A) and a hoist to lift the flywheel housing and engine enough so that the washers between the oil pan and the cylinder block can be removed.7. Remove the block from under the oil pan. Put blocks under the flywheel housing for support. Lower the engine down on to the blocks.8. Tighten bolts (5) that hold oil pan (4) to the cylinder block. Install the six bolts that hold the oil pan to the flywheel housing. 9. Install plate (6) and adapter (7). 10. Install turbocharger and manifold (8) as a unit on the plate. The weight of the turbocharger and manifold is approximately 72 kg (158 lb.). Step 11 is for engines that have watercooled exhaust manifolds and turbochargers.11. Make sure gaskets (9) and (10) are in position.12. Put 5P3931 Anti-Seize Compound on the threads of the studs that hold the turbocharger and manifold to plate (6). Install the four nuts that hold it in place. Tighten the nuts to a torque of 30 5 N m (22 4 lb.ft.). Steps 13 through 15 are for engines with watercooled exhaust manifolds and