848509 Volvo.Penta Housing

1. Remove plate (1) from the left side of the flywheel housing. Bolt (2) is also the timing bolt for the flywheel.2. There are two ways the engine can be turned. The first way is as follows: a) Remove bolts (4) that hold pinion (3) and spacer (5) to the flywheel housing.b) Install pinion (3) in the flywheel housing. Use a 1/2" ratchet and turn the engine.3. The second way is as follows: a) The retainer (6) that holds the vibration damper and hub on the crankshaft has a 1 1/8" nut welded to it.b) Use a 1 1/8" socket and turn the engine. This will take two persons to do this procedure. 4. Turn the engine clockwise (as seen from the flywheel) approximately 30° to remove the play in the timing gears. Turn the engine counterclockwise (as seen from the flywheel) until the threaded hole in the flywheel is in alignment with the hole in the flywheel housing and bolt (2) can be installed in the flywheel. The No. 1 piston is at top center compression stroke.5. The intake and exhaust valves for No. 1 cylinder on the right side of the engine must be free to move by hand. If not, it will be necessary to turn the engine counterclockwise (as seen from the flywheel) 360° more and install bolt (2) again. If the hole in the flywheel is turned beyond the hole in the flywheel housing, turn the engine clockwise (as seen from the flywheel) a minimum of 30° before the engine is turned counterclockwise (as seen from the flywheel) to install bolt (2).6. Install timing pin (10) in the right intake camshaft.7. Remove bracket (9) and seal (7) (left camshaft housing only). Remove engine oil filter base support (not shown) and seal (right camshaft housing only).
TYPICAL EXAMPLE8. Remove cover (8) from the camshaft housing. 9. Remove four bolts (11) that hold the camshaft housing to the cylinder head. 10. Remove bolts (12) from the top and the sides that hold the exhaust manifold shields in place. Remove strip (13). 11. Remove bolts (14) that hold elbow (15) to the aftercooler cover. Loosen the clamp on the turbocharger and turn elbow (15) away from the aftercooler cover. 12. Remove cover (16) and seal from the camshaft housing. 13. Disconnect wire (17) for the glow plugs from the terminal on the camshaft housing.14. Disconnect glow plug wire harness (18) from the glow plugs. Remove bolt (19) and clamps that hold the tube assemblies in place. 15. Remove inner fuel lines (20). Put caps or plugs on the openings.16. Disconnect tubes (21). 17. Install tooling (A) and fasten a hoist. Remove bolts (23) that hold the camshaft housing to the cylinder head. Remove camshaft housing (22). The weight is approximately 150 lb. (68 kg). 18. Remove O-ring seals (24) and (25) from the cylinder head.Install Camshaft Housing
1. Inspect all parts and make replacements if needed.2. Make an adjustment to all valve adjustment screws for maximum valve clearance.3. Make sure the timing marks on the drive gears for the camshafts are in alignment and the timing pin is installed in the inlet camshaft.4. Make sure the No. 1 piston is at top center compression stroke and the timing bolt is installed in the flywheel.
If above procedure in Steps 2 through 4 are not followed, damage to the engine can be the result.
5. Install O-ring seals (1) and (2) on the cylinder head. 6. Put a new gasket (4) in position. Install tooling (A) and fasten a hoist to the camshaft housing. Put camshaft housing (3) in position on the cylinder head. Make sure the camshaft gear teeth are engaged in the teeth of the drive gear in the cylinder head. Install the bolts that hold the camshaft housing to the cylinder head. 7. Install tubes (5). 8. Remove the caps or plugs from the openings. Install inner fuel lines (6). Tighten the fuel lines to a torque of 30 5 lb.ft. (40 7 N m). 9. Connect wires (7) to the glow plugs. 10. Connect wire (8) for the glow plugs to the terminal on the camshaft housing.
Seal (9) must be installed. If the seal is not installed in its correct position, fuel can go into the area of the exhaust manifold when air is removed from the fuel lines. Fire can be the result.
11. Install seal (9) and gasket on cover (10). Install cover (10). 12. Put clamp (11) in position and install the bolt that holds the clamp to the camshaft housing. 13. Put elbow (12) in position against the aftercooler cover. Install the gasket and bolts that hold the elbow to the aftercooler cover.14. Tighten the clamp on the turbocharger to a torque of 10.3 1.11 lb.ft. (14 1.5 N m). Hit the clamp lightly all around and tighten again to 10.3 1.11 lb.ft. (14 1.5 N m). 15. Put strip (13) in position and install the bolts that hold the manifold shields to the camshaft housing. 16. Install bolts (14) at each end that hold the exhaust manifold shields in place.17. Install the gasket and cover (16).
Seal (15) must be installed. If the seal is not installed in its correct position, fuel can go into the area of the exhaust manifold when air is removed from the fuel lines. Fire can be the result.
18. Install seal (15) and bracket (17) (left camshaft housing only). (On the right camshaft housing, the engine oil filter base support holds the seal in position).19. Remove the timing pin from the inlet camshaft. 20. Remove timing bolt (17) from the flywheel.21. Make an adjustment to the valve. See TESTING AND ADJUSTING. 22. Remove pinion (18). Install spacer (19) and pinion (18) in the flywheel housing. Install plate (20) on the left side of the flywheel housing.end by:a) install engine oil filter base (right camshaft housing only)b) install fuel injection linesc) install valve covers