978281 Volvo.Penta Nipple

Table 1
Required Tools
Tool Part Number Part Description Qty
A 238-9586 Camshaft Drive Group 1
B 1P-0820 Hydraulic Puller 1
8B-7548 Push-Puller Tool Group 1
8B-7559 Adapter 2
5H-1504 Hard Washer 3
9U-6600 Hand Hydraulic Pump 1
C 125-0200 Camshaft Pilot As 2
D 525-1832 Camshaft Guide As 1
E 8T-3169 Crank Assembly 1 Start By:
Remove valve cover base.
Remove speed/timing sensor.
Remove electronic control module.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g06058664
Remove bolts (1) and camshaft covers (2).
Illustration 2 g06058699
Remove bolts (3) and covers (4).
Illustration 3 g06058772
Remove bolt (8), bolt (7), camshaft ring gear (5), and plate (10).
Place three washers from Tooling (B) behind plate (10) and install bolt (7).
Do not apply more than 51675 kPa (7500 psi) pressure to the hydraulic puller. The adapters are rated at 6 1/2 tons each and the hydraulic puller is rated at 17 tons at 68900 kPa (10000 psi). If too much pressure is applied, the gear may be damaged.
Install Tooling (B) on camshaft drive gear (6). Apply 51675 kPa (7500 psi) to Tooling (B). Strike the screw on Tooling (B) with a hammer until camshaft drive gear (6) is free from the camshaft. Remove Tooling (B) and camshaft drive gear (6).
Repeat Step 4 through Step 5 for camshaft drive gear (9).
Illustration 4 g06058952
Remove bolts (11) and cam plate (12).
Illustration 5 g06058988
Install Tooling (C) on the end of the camshaft.
Install Tooling (D) on the flywheel housing.
Install Tooling (E) on the end of Tooling (C).
The combined weight of camshaft (13) and camshaft (14) is approximately 70 kg (154 lb).
Rotate the camshaft with Tooling (E). Pull the camshaft out of the engine until a suitable lifting device can be attached. Remove the camshaft.
Illustration 6 g06059235
Remove bolts (15). Separate the camshafts and remove spacer (16).
Remove the dowel from the front of the camshaft if necessary.
Repeat Steps 8 through Step 14 for the other camshaft.Installation Procedure
Note: Ensure that the camshafts are assembled and installed according to the marks on the ends of the camshafts.
Install Tooling (D) on the flywheel housing. Do not tighten the bolts on Tooling (D).
Install Tooling (C) on the end of the front half of the camshaft.
Ensure that the camshaft and the camshaft bearings are clean. Place clean engine oil on the lobes and the journals of the camshaft. Also place clean engine oil on the camshaft bearings.
Attach a suitable lifting device to the camshaft. The weight of one-half of the camshaft is approximately 40 kg (88 lb).
Position the front half of camshaft (13) in the engine until Tooling (C) is in the first camshaft bearing.
Rotate camshaft (13) and tighten the bolts for Tooling (D).
Rotate camshaft (13) and insert the camshaft until the camshaft is slightly protruding from Tooling (D).
If the dowel was removed from the front half of camshaft (13), install the dowel. Install the dowel to 22 0.5 mm (0.9 0.02 inch) from the surface of the camshaft.
Illustration 7 g06059235
Attach a suitable lifting device to rear half of camshaft (13). The weight of one-half of the camshaft is approximately 36 kg (80 lb). Install spacer (16) and the rear half of camshaft (13) onto the front half of camshaft (13). Install bolts (15) and tighten to a torque of 55 7 N m (41 5 lb ft).
Install Tooling (C