860720 Volvo.Penta Gear

Safety Section
Before performing any of the following procedure, ensure that the machine has been properly locked out/ tagged out.
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, NENG2500, "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.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Removal Procedure
Set the engine to Top Dead Center (TDC) for number 1 piston. Refer to Testing and Adjusting, UENR4352, "Finding Top Center Position for No. 1 Piston".
Illustration 1 g03842779
(1) 438-5193 Hose Clamp (2) 452-1783 Hose (3) 451-9183 Air Filter Gp (4) 439-7464 Bolts (5) 439-7202 Bolts (6) 439-5566 Tube As (7) 463-7537 Heat Shield As (8) 439-5569 Tube As (9) 442-9570 Water Lines Gp
Loosen hose clamp (1) from hose (2).
Disconnect the sensors for air filter group (3) .
Loosen the clamp for air filter group (3). Remove the air filter group along with hose (2) .
Loosen water lines group (9) from the top of the turbocharger and move out of the way.
Remove bolts (4) from tube assembly (8) and move the tube assembly out of the way.
Remove bolts (5) from tube assembly (6) and move the tube assembly out of the way.
Remove heat shield (7) from the exhaust side of the turbocharger.
Illustration 2 g03843002
(10) 449-0833 Band Clamp (11) 439-0502 Band Clamp
Remove band clamps (10) and (11) from the turbocharger.
Illustration 3 g03843042
(13) 439-0447 Turbocharger Gp (14) 439-1039 Nuts
Remove four nuts (14) to remove turbocharger group (13) 15 kg (33 lb).
Illustration 4 g03843065
(15) 438-6107 Fuel Lines Gp (16) 438-6053 Bolts (17) 438-6036 Fuel Filter Gp (18) 451-8589 Engine Oil Filter Gp (19) 439-7195 Bolts (33) 438-5186 Bolts
Remove fuel lines group (15) .
Remove engine oil filter group (18) by removing four bolts (19) and bolts (33) attached to the side of the base.
Remove fuel filter group (17) by removing four bolts (16) .
Illustration 5 g03843293
(20) 434-7530 Bolts (21) 438-7229 Flywheel Housing Cover Assembly (22) 438-5207 Hose (23) 438-5192 Hose Clamp
Remove hose clamp (23) and then move hose (22) out of the way.
Remove bolts (20) in order to remove flywheel housing cover assembly (21) .
Illustration 6 g03843360
(24) 450-0589 Bolts (25) 431-5073 Valve Cover
Remove bolts (24) in order to remove valve cover (25) .
Illustration 7 g03843381
(26) 433-7050 Nuts (27) 433-7049 Bolts
Loosen nuts (26) and then loosen bolts (27) to allow for removal of the camshaft. Make sure that the camshaft will be able to clear the rollers located on the back of the rocker arm mechanisms.Note: Make sure that the camshaft will be able to clear the rollers located on the back of the rocker arm mechanisms.
Illustration 8 g03843392
(28) 438-0903 Bolts (29) 431-4120 Camshaft Gear