820459 Volvo.Penta Pulley

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     8T-3029     Camshaft Support     1    
1U-6311 Plate     1    
B     1P-2382 (1)     Wrench Adapter     1    
9U-5932 (1) Torque Wrench Extension     1    
C     6V-6080     Torque Multiplier Gp     1    
5P-1748 Socket     1    
( 1 ) Only one tool is required. Be sure that the proper tool is used for your engine.Start By:
Remove the governor actuator. Refer to Disassembly and Assembly, "Governor Actuator - Remove and Install".
Remove the valve lifter groups. Refer to Disassembly and Assembly, "Valve Lifter - Remove".
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Refer to Disassembly and Assembly, "General Information (Reference Material)" for more information.
Illustration 1 g00575670
Illustration 2 g00575675
Remove the camshaft inspection covers from the side of the cylinder block.Note: The engine must be rotated in order to remove all of the bolts that hold camshaft segment (4) in position.
Use Tooling (B) in order to loosen bolts (1) on the outside of camshaft segment (4) .
If it is necessary to remove camshaft journal (2), loosen bolts (3) on the outside diameter.
Rotate the engine until bolts (1) and bolts (3) that were toward the inside of the cylinder block are on the outside.
Loosen remaining bolts (1) and bolts (3) .
Illustration 3 g00575676
Note: Identify the proper orientation of the camshaft segments and the camshaft journals for installation purposes.
Install Tooling (A) under camshaft segment (4) .
Remove bolts (1) that hold camshaft segment (4) in position.
Carefully move the front section of the camshaft toward the front of the engine. This is done in order to disengage the dowels in each end of the camshaft segment.
Carefully move camshaft segment (4) out of the engine on Tooling (A) .
Attach a suitable lifting device to camshaft segment (4). The weight of camshaft segment (4) is approximately 28 kg (62 lb). Remove the camshaft segment from Tooling (A). Use a paint stick to put identification marks on the camshaft segment for proper installation.
Remove the spacers from each camshaft journal. Remove Tooling (A) from the engine.
Remove bolts (3) that hold camshaft journal (2) to the other camshaft segment.
Slide camshaft journal (2) out of the camshaft bearing. Remove the camshaft journal from the engine. Remove the spacer from the journal.
Illustration 4 g01421677
Note: The engine can not be rotated after camshaft drive gear (5) is removed. Ensure that all of the necessary bolts have been loosened before the camshaft drive gear is removed.
Engage and lock the manual barring group in order to prevent the rotation of the crankshaft when bolt (7) is loosened. Refer to Systems Operation, "Manual Barring Group".
Remove the timing pins from the crankshaft and the camshaft.
Use Tooling (C) in order to loosen bolt (7) .
Remove bolt (7) and washer (8) .
Remove bolts (6) and plate (9) .
Put washer (8) between the camshaft and plate (9). Install bolt (7) .
Install bolts (6) hand tight.Note: Ensure that bolt (7) is installed in order to hold camshaft drive gear (5) when the camshaft drive gear is pulled off the taper of the camshaft.
Tighten bolts (6) evenly in order to pull camshaft drive gear (5) off the taper of the camshaft.
Attach a suitable lifting device to camshaft drive gear (5). The weight of camshaft drive gear (5) is approximately 35 kg (77 lb). Remove bolts (6), bolt (7), plate (9), and washer (8). Remove camshaft drive gear (5) from the rear housing.
Illustration 5 g01425667
Remove coupling (12) .
Remove the bolts that hold pinion assembly (11) to rear housing (10) .Note: Do not bend shims (13) when pinion assembly (11) is removed.
Remove pinion assembly (11) and shims (13) from rear housing (10) .
Remove O-ring seals (14) from pinion assembly (11) .
Illustration 6 g01425662