977004 Volvo.Penta O-ring

1. Remove the four bolts and clamps (1) from the support. 2. Fasten a hoist and a 1/2" - 13 NC forged eyebolt to support (2). Remove the ten bolts and support (2). The weight of the support is 69 Kg (152 lb.). 3. Remove four tubes (4) from the engine.4. Remove elbow (5) and tube (3) as a unit from the engine. 5. Remove cover (6) from the front drive housing. Remove the O-ring seal from cover (6). 6. Remove the bolts and use tooling (A) to remove shaft (8) and idler gear (7) from both sides of the front drive housing.7. Use tooling (B) and a press to remove the bearing from idler gear (7). 8. Remove two washers (9) from the inside of the front drive housing.9. Remove all of the bolts that hold the oil pan to the engine. Install 3/8" - 16 NC guide bolt in each side of the oil pan. Fasten a hoist to the engine and lift the engine approximately 12 mm (0.5 in.) off of the oil pan. Put two 50 mm wide x 100 mm long x 6 mm thick (2 in. wide x 4 in. long x 1/4 in. thick) plates in position between the cylinder block and the oil pan on each side of the engine. Lower the engine remove the hoist. The weight of the 3512 Engine is approximately 5,443 Kg (12,000 lb.). The weight of the 3516 Engine is approximately 6,447 Kg (14,200 lb.).
Typical Example10. Fasten a hoist to front drive housing (9) with tooling (C). Remove the bolts and front drive housing (9) from the engine. The weight of the housing is 209 Kg (460 lb.).Install Front Drive Housing
Typical Example1. Put the front drive housing gasket in position on the front of the cylinder block. Install two 5/8" -NC guide bolts in the cylinder block.2. Fasten a hoist to front drive housing (9) with tooling (C). Put housing (9) in position on the guide bolts and install the bolts that hold it in position. Remove the guide bolts and install the remainder of the bolts. Tighten all of the bolts evenly and cut the housing gasket even with the bottom of the cylinder block.3. Fasten a hoist to the engine and lift the engine enough to remove the plates between the cylinder block and the oil pan. If the oil pan gasket is damaged, the engine will have to be removed from the oil pan to make a replacement of the gasket. Lower the engine on the oil pan and remove the guide bolts from the oil pan. Install all of the bolts that hold the oil pan to the engine. 4. Put two washers (9) inside the front drive housing. 5. Use tooling (B) and a press to install the bearing in idler gear (7). Check the bore in the bearing after assembly. The bore in the bearing must be 90.00 0.06 mm (3.543 .002 in.).6. Put clean engine oil on the O-ring seal of shaft (8). Install idler gear (7) and shaft (8) on both sides of the front drive housing. 7. Put clean engine oil on the O-ring seals and install cover (6) on the front drive housing. 8. Lubricate the O-ring seals on tube (3) with Glycerin. Install tube (3) and elbow (5) as a unit on the engine.9. Install four tubes (4) on the engine. 10. Use a 1/2" -13 NC forged eyebolt and a hoist to position support (2) on the front drive housing. Install the bolts that hold the support in position. 11. Install four clamps (1) and the bolts that hold the tubes.End By:a. install oil and water pump driveb. install accessory drive (front)c. install front crankshaft seal and wear sleeved. install governor drivee. install oil filter housing