875461 Volvo.Penta Overhaul kit

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Guide Studs M10 by 100 mm 2 Start By:
Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove" for the correct procedure.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
There are five types of flywheel housing that can be installed on the engine. The removal procedures for all types of flywheel housing are similar but all the installation procedures are different.Ensure that you use the correct procedure and the correct grades of bolts for your application.
Illustration 1 g06059374
Typical example
Remove bolts (2) from Positions (X) in flywheel housing (3).
Install Tooling (A) into Position (X) to flywheel housing (3).
Install a suitable lifting device onto flywheel housing (3) to support the flywheel housing. The weight of the flywheel housing is approximately 40 kg (88 lb).
Remove remaining bolts (2) from flywheel housing (3).
Remove bolts (1) from flywheel housing (3).
Use the lifting device to remove flywheel housing (3) from the cylinder block.
Illustration 2 g06060478
Typical example
Remove dust seal (5).
If necessary, remove dowels (4) from the cylinder block.Installation Procedure of Type E Flywheel Housing
Table 2
Required Tools
Tool Part Number Part Description Qty
A - Guide Studs M10 by 100 mm 2
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the flywheel housing is clean and free from damage. If necessary, replace the flywheel housing.
Illustration 3 g06060473
Positions for Tooling (A).
Inspect the crankshaft rear seal for leaks. If there are any oil leaks, replace the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear Seal - Remove" and refer to Disassembly and Assembly, "Crankshaft Rear Seal - Install" for the correct procedures.
Clean the rear face of the cylinder block. If necessary, install dowels (4) to the cylinder block.
Install Tooling (A) in Positions (X) to the cylinder block.
Install new dust seal (5).
Illustration 4 g06060490
Type E flywheel housing
Bolts (1) are 12 mm
Bolts (2) are 10 mm
Illustration 5 g06060507
Tightening sequence of Type (E) flywheel housing
Ensure that bolts (1) and bolts (2) are clean and free from oil and grease. Ensure that all threaded holes in the cylinder block are clean and free from oil and grease.The threads of the bolts and the threads in the cylinder block must be clean and dry to prevent too higher torque being applied.
Install a suitable lifting device onto the flywheel housing. The weight of the flywheel housing is approximately 40 kg (88 lb).
Use the lifting device to align flywheel housing (3) with Tooling (A). Install the flywheel housing to the cylinder block.
Install bolts (1) and bolts (2) to the flywheel housing.
Remove Tooling (A). Install remaining bolts (2).
Follow Step 11.a through Step 11.b to tighten bolts (1) and bolts (2) in the tightening sequence that is shown in Illustration 5.
Tighten bolts (1) to a torque of 78 N m (58 lb ft).
Tighten bolts (2) to a torque of 63 N m (46 lb ft).
Check the alignment of flywheel housing (3) with the crankshaft. Refer to System Operation, Testing and Adjusting, "Flywheel Housing - Inspect" for more information.End By:
Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install" for the correct procedure.