880778 Volvo.Penta Thermo contact

Table 1
Required Tools
Tool Part Number Part Description Qty
A 9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
B 230-6284 Timing Pin (Camshaft) 1
C 364-9107 Timing Pin (Fuel Injection Pump) 1
D 136-4632 Timing Pin (Crankshaft) 1
268-1966 Adapter 1
E 298-5564 T40 Torx Socket 1 Start By:
Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install" for the correct procedure.
Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Note: Care must be taken in order to ensure that the fuel injection pump timing is not lost during the removal of the front gear group. Carefully follow the procedure in order to remove the gear group.
If the air compressor is equipped with a hydraulic pump, remove the hydraulic pump. Refer to Original Equipment Manufactures (OEM) for the correct procedure.
If the engine is equipped with an air compressor, remove the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove" for the correct procedure.
If the engine is equipped with only a hydraulic pump, remove the hydraulic pump. Refer to OEM for the correct procedure.
Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. Note: Do not use excessive force to install Tooling (D). Do not use Tooling (D) to hold the crankshaft during repairs.
Illustration 1 g02486477
Remove plug (1) from the cylinder block. Remove O-ring seal (2) from the plug.
Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. Install Tooling (D) through Hole (W) in order to lock the crankshaft so that number one piston is at top dead center on the compression stroke.
Remove Tooling (D).
Use Tooling (A) in order to rotate the crankshaft in a clockwise direction and position the crankshaft at the safe position. Refer to System Operation, Testing and Adjusting, "Position the Valve Mechanism Before Maintenance Procedures" for the correct procedure.
Illustration 2 g03706901
Use Tooling (E) in order to loosen threaded inserts (4) on all rocker arms (3). Unscrew threaded inserts (4) on all rocker arms (3) until all valves are fully closed. Note: Ensure that ALL threaded inserts are fully unscrewed.
Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. Install Tooling (D) through Hole (W) in order to lock the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to Illustration 17.
Illustration 3 g03706903
Install Tooling (B) through Hole (X) in camshaft gear (5) into the front housing. Use Tooling (B) in order to lock the camshaft in the correct position. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure.
Use Tooling (C) in order to lock the fuel injection pump gear in the correct position. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove" for the correct procedure.
Illustration 4 g03706905
If the right-hand side of the engine is equipped with a hydraulic pump, remove the hydraulic pump. Refer to OEM for the correct procedure.
If necessary, remove bolts (6) from plate (7). Remove plate (7) and remove O-ring seal (8).
Remove circlip (9) and remove gear assembly (10) from front housing (11).
Illustration 5 g03706906
If necessary, follow Step 16.a through Step 16.b in order to disassemble gear assembly (10).
Remove circlip (12) from gear assembly (10).
Place gear assembly (10) on a suitable support. Press bearing (13) from