3580848 Volvo.Penta Inlet pipe

Table 1
Required Tools
Tool Part Number Part Description Qty
A 6V-6080 Torque Multiplier 1
5P-1748 Socket 1
4C-9451 Rear Idler Gear Wrench 1
4C-9452 Rear Idler Gear Wrench 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Remove the camshaft drive gear cover from the left side of the rear housing.
Illustration 1 g03816482
Remove the rear camshaft inspection cover from each side of the engine. Note: The center lobe on the camshaft segment of the G3612 and the G3616 Engine is narrower than the camshaft segment of the 3612 or 3616 Diesel Engine.Note: Bolts (2) must be loosened before the camshaft drive gears are removed.
Loosen bolts (2) that hold drive shaft (1) to camshaft segment (3). Loosen as many of the bolts as possible on each camshaft.
Use the manual barring group and rotate the engine until remaining bolts (2) can be loosened on each camshaft.
Illustration 2 g00610660
Remove the four bolts and cover (4).
Remove crankshaft timing pin (5) from the storage location. Note: Be sure that the holes for the camshaft timing pin are aligned when the crankshaft timing pin is installed.
Use the manual barring group and rotate the engine until the crankshaft timing pin can be installed in the timing location.
Illustration 3 g00663997
Remove camshaft timing pins (6) from storage. Install these pins in the location for the camshaft timing. Note: The center lobe on the camshaft segment of the G3612 and the G3616 Engine is narrower than the camshaft segment of the 3612 or 3616 Diesel Engine.
Illustration 4 g00610671
Engage and lock the manual barring group in order to prevent the rotation of the crankshaft when bolts (9) are loosened. Note: In order to prevent damage to the camshaft timing pins, remove the pins when bolts (9) are loosened.
Use Tooling (A) and loosen bolt (9) on each camshaft.
Remove bolts (9) and washer (10).
Remove bolts (8) and plate (11) from camshaft drive gear (7).
Put washer (10) in position between the camshaft and plate (11). This position is shown in Illustration 4.
Install bolts (8) hand tight. Note: Be sure that bolt (9) is installed. This installation will prevent the camshaft drive gears from falling as the gears are loosened from the taper on the camshaft.
Tighten bolts (8) evenly in order to loosen camshaft drive gears (7) from the taper on the camshafts.
Attach a suitable lifting device to camshaft drive gear (7). Remove bolt (9).
Remove bolt (8) and other bolt (9) from plate (11) and washer (10).
Remove camshaft drive gears (7) from the rear housing. The weight of the camshaft drive gear is approximately 35 kg (77 lb).
Illustration 5 g00610676
Remove bolts (13) and plate (12) from drive shaft (1).
Remove bolts (14) and plate (15).
Illustration 6 g03816511Note: The center lobe of the camshaft segment of the G3612 and the G3616 Engine is narrower than the camshaft segment of the 3612 or 3616 Diesel Engine.
Remove bolts (2) that hold drive shaft (1) to camshaft segment (3).
Attach a suitable lifting device to drive shaft (1). Remove the drive shaft (1). The weight of drive shaft (1) is 40 kg (88 lb).
Illustration 7 g03816532
Illustration 8 g03816542
Attach a suitable lifting device to gear (21). Remove bolts (19). Move shaft (18) away from the cylinder block. Remove the shaft and gear (21) out of the camshaft drive gear opening in the rear housing. The weight of the shaft and the gear is approximately 41 kg (90 lb).
Remove the bolts and retainer (22). Remove gear (21) from shaft (18).
If necessary, remove the bearing from gear (21).
Repeat Step 23 through Step 25 for the other idler gear. Note: Retainer (20) and gear (16) must be moved away from shaft (23) in order to remove lower bolts (24).
Loosen bolts (17). Move retainer (20) and gear (16) toward the rear.
Attach a suitable lifting device to gear (16) through the opening for the accessory drive in the rear housing. Support the weight of the gear with the suitable lifting device.
Remove four bolts (24). Move shaft (23) away from the cylinder block.
Move the shaft and gear (16) upward toward the camshaft drive gear opening in the rear housing.
Attach a suitable lifting device to gear (16) through the cam