1542283 Volvo.Penta Stud

Start By:a. separate torque converter and engineb. remove electric starting motorsc. remove oil pan, (rear half only)d. remove crankshaft rear seal and wear sleeve **Refer to 3500B Engines For Caterpillar Built Machines Disassembly & Assembly module, SENR1126, for this procedure. Use a 9S-9082 Engine Turning Tool to turn the flywheel in the direction of normal engine rotation and install timing pins in the camshafts before the flywheel is removed. 1. Use a suitable lifting device to lift the engine. Put stands [Tool (A)] or wooden blocks under the engine block to support the engine in a safe manner for removal of flywheel housing (1). The weight of the engine is 4445 kg (9800 lb). 2. Remove ten bolts and washers (2).3. Remove cover (3). Check the condition of gasket (4) beneath cover (3) and replace as needed. 4. On the left side of the engine, cut tie-wraps (8).5. Unplug connector (10).6. Remove magnetic sensor (11).7. Pull electrical connector (6) from mounting clip (5).8. Lay wiring harness (7) aside. 9. Remove ten bolts and washers (12).10. Remove cover (13). Check the condition of gasket (14) beneath cover (13) and replace as needed.11. Remove wire hanger (15) and clip (16).12. Disconnect speed/timing sensor (17). 13. Remove bolt and washer (18).14. Remove timing ring (19). 15. Use Tooling (D) to remove camshaft gear (20) from left side camshaft (21). 16. Remove the bolt and plate holding camshaft gear (27) to the camshaft.17. Use Tooling (D) to remove camshaft gear (27) from the right side camshaft.18. Cut tie-wraps (25) and lay wiring harness (26) out of the way.19. Remove twenty bolts and washers (22), top cover (24) and gasket (23) from the top of the flywheel housing. 20. Attach Tooling (B), safety chains, and a suitable lifting device to the top of flywheel housing as shown.21. Remove two flywheel housing bolts (28). 22. Install Tool (C) (Guide Bolts) in the place of the two bolts removed in the previous step.23. Remove the remainder of flywheel housing bolts (28) from flywheel housing (1). There are nine partially hidden bolts (28) inside the flywheel housing and behind the gears. 24. Carefully remove flywheel housing (1) from the cylinder block. The weight of flywheel housing (1) is approximately 300 kg (660 lb).25. Remove O-ring seal (29) from cylinder block (30).26. If necessary, remove idler gear (31) from flywheel housing (1).27. If necessary, remove dowel pins (32). The following steps are for the installation of the flywheel housing.28. Use 4C-9500 Quick Cure Primer to clean the mating surfaces of the flywheel housing and the cylinder block. Put 4C-5300 Gasket Maker on the mating surfaces of the flywheel housing and the cylinder block. 29. If idler gear (31) was removed, install the idler gear in the flywheel housing.30. If the dowel pins were removed, install the dowel pins to a height of 3.5 0.5 mm (.14 .02 in). Make sure the dowel pins are properly seated.31. Install O-ring seal (29) in its original location.32. Attach Tooling (B), safety chains, and a suitable lifting device to the top of flywheel housing (1) as shown. The weight of flywheel housing (1) is approximately 300 kg (660 lb). 33. Install the bolts for flywheel housing (1) in their respective locations. See the Installation Chart. Tighten the 1/2 in - 13 NC Bolts to a torque of 135 15 N m (100 10 lb ft). Tighten the 5/8 in - 11 NC Bolts to a torque of 270 25 N m (200 18 lb ft).34. Remove Tooling (B).35. Put the camshaft timing pins in position and put the timing bolt in the flywheel with number 1 piston at top center compression stroke. See the topic "Install Camshafts" in 3500B Engines For Caterpillar Built Machines Disassembly & Assembly module, SENR1126. Be sure gear backlash is removed.36. Install the two camshaft drive gears.37. Install the bolt and plate on the right side camshaft gear.38. Install gasket (23) and top cover (24) on the top of the flywheel housing. Install twenty bolts and washers (22).39. Put wiring harness (26) in position and install new tie-wraps (25). 40. Position timing ring (19) on the camshaft. Install washer and bolt (18) for timing ring (19).41. Use the following steps to seat the camshaft gears on the tapered ends of the camshafts: a. Tighten the bolt holding timing ring (19) to a torque of 360 50 N m (265 35 lb ft).b. Use a soft hammer to hit the head of the bolt holding timing ring (19). This will help seat the camshaft drive gear on the camshaft.c. Again tighten the bolt holding timing ring (19) to a torque of 360 50 N m (265 35 lb ft). Put a mark on the bolt and timing ring (19).d. Repeat Steps b and c until the bolt holding timing ring (2) no longer moves (the marks stay aligned) after reaching the proper torque.e. Repeat Steps a through d to seat the remaining camshaft drive gear.42. Remove the timing pins from the camshafts. 43. Install gasket (14) and cover (13) on the flywheel housing.44. Install wire hanger (15) and clip (16).45. Install ten bolts and washers (12).46. Connect speed/timing sensor (17). Tighten speed/timing sensor (17) to a torque of 40 5 N m (29 4 lb ft). For more detailed information, see the topic "Installation/Removal Of The Speed/Timing Sensor" in Systems Operation Testing & Adjusting Manual SENR1123. 47. Put wiring harness (7) in position.48. Plug in connector (10).49. Push electrical connector (6) in mounting clip (5).50. Install magnetic sensor (11). Tighten the locknut on the magnetic sensor to a torque of 25 5 N m (18 4 lb ft). For more detailed information, see the topic "Magnetic Pickup" in Specifications Manual SENR1122.51. Install new tie-wraps (8). For additional information, see the topic "Flywheel Housing" in Specifications Manual SENR1122, also see the topic "Flywheel And Flywheel Housing" in Systems Operation Testing & Adjusting Manual SENR1123.End