276151 Volvo.Penta Overhaul kit

1. Remove plate (1) from the left side of the flywheel housing. Bolt (2) is also the timing bolt for the flywheel. 2. Remove bolts (4) that hold pinion (3) and spacer (5) to the flywheel housing. 3. Install pinion (3) in the flywheel housing. Use a 1/2" ratchet to turn the engine.4. Turn the engine clockwise (as seen from the flywheel) approximately 30° to remove the play in the timing gears. Turn the engine counterbore (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 (9) in the intake camshaft. 7. Install a hoist on pipe (6). Remove the pipe and the support as a unit. Weight is 62 lb. (28 kg). 8. Remove elbow (8). Remove shield (7). 9. Remove bracket assembly (10) and seal (11). 10. Remove bracket (12) and seal (13) (left assembly housing only). Remove engine oil filter base support (not shown) and seal (right camshaft housing only).11. Remove cover (14) from the camshaft housing. 12. Remove bolts and locks (15).13. Remove tubes (18).14. Remove fuel lines (17). 15. Disconnect wires (16) from the glow plugs. Disconnect the wire (not shown) for the glow plugs from the terminal on the camshaft housing. 16. Install two 3/8"-16 NC forged eyebolts and a hoist on the camshaft housing. Remove the bolts that hold the camshaft housing in position. Remove the camshaft housing. Weight is 150 lb. (68 kg).Install Camshaft Housing
1. Clean and inspect all parts. Make a replacement of all parts that are worn or damaged.2. Adjust all valve adjustment screws for maximum valve clearance.3. Make sure the timing marks on the drive gears (7) for the camshafts are in alignment and install timing pin (5) in the camshaft.4. Check to be sure that the crankshaft is at top center compression stroke for No. 1 piston and the timing bolt is installed in the flywheel.
If above procedure in Steps 1 to 3 are not followed, damage to the engine can be the result.
5. Put gasket (1) in position. Use a hoist to put the camshaft housing in position on the engine. Make sure the camshaft gear teeth are engaged in the teeth of the drive gear. Install the bolts, nuts and locks that hold the camshaft housing in position.6. Install tubes (4). 7. Connect wires (2) to the glow plugs. Connect the wire (not shown) for the glow plugs to the terminal on the camshaft housing. 8. Install fuel lines (3). Tighten the nuts to a torque of 30 5 lb.ft. (40 7 N m).9. Install gasket and cover (6).
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.
10. Install seal (9) and bracket (8) (left camshaft housing only). (On the right camshaft housing, the engine oil filter base support holds the seal in position).
Seal (11) 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 (11) and bracket assembly (10). 12. Put shield (12) and elbow (13) in position. 13. Install pipe (14) and the support on the engine.14. Remove the timing pin from the inlet camshaft.
TYPICAL EXAMPLE15. Remove timing bolt (15) from the flywheel.16. Make an adjustment to the valves. See TESTING AND ADJUSTING.
TYPICAL EXAMPLE17. Remove pinion (16). Install spacer (17) and pinion (16) in the flywheel housing. Install plate (18) on the left side of the flywheel housing. end by:a) install exhaust manifold shieldb) install engine oil filter base (right camshaft housing only)c) install fuel injection linesd) install turbochargerse) install valve covers