3801213 Volvo.Penta Upper gear, exch, complete

Start By:
Remove the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Remove".
Remove the auxiliary water pump. Refer to Disassembly and Assembly, "Auxiliary Water Pump - Remove".
Remove the unit injector hydraulic pump. Refer to Disassembly and Assembly, "Unit Injector Hydraulic Pump - Remove".
Remove the rocker arms and pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove".
Remove the electronic control module (ECM). Refer to Disassembly and Assembly, "Electronic Control Module - Remove and Install".
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.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g00640138
Remove bolt (1) that holds the bracket for the engine speed/timing sensor to the timing gear housing. Remove two engine speed/timing sensors (3) and the bracket from the timing gear housing.
Cut the straps that hold the wiring harness to side cover (2) of the cylinder block.
Remove the bolts that hold side cover (2) to the cylinder block.
Illustration 2 g00611182
Remove the bolts and side covers (4) and (5) from the cylinder block.
Illustration 3 g00611184
Note: Ensure that the sleeves of the side covers remain in the side covers.
Remove four bolts (6) and the dowels that hold the lifter arms (7) and the lifter shaft (8) to each side cover. Remove gasket (9) .Installation Procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 4 g00611184
Install gasket (9) .
Install lifter arms (7) on lifter shaft (8) .
Position lifter shaft (8) and the dowels on the side cover. Ensure that the oil holes in the lifter shaft are facing the side cover. Apply 9S-3263 Thread Lock Compound on the threads of bolts (6) that hold lifter shaft (8) to the side cover. Install bolts (6). Tighten bolts (6) to a torque of 13 3 N m (10 2 lb ft). Tighten the two center bolts. Then tighten the end bolts.
Lubricate the lifters with clean engine oil.
Ensure that the cylinder block and the sealing surfaces of the side cover are thoroughly clean. Apply 1U-8846 Sealant to the sealing surfaces of the side cover. The side covers must be installed on the cylinder block within 10 minutes of applying the sealant.
Illustration 5 g00611182
Illustration 6 g00640138
Position the gaskets and side covers (2), (4), and (5) on the cylinder block. Install the bolts and clips that hold the side covers in position.
Install two engine speed/timing sensors (3) and the bracket to the timing gear housing. Install bolt (1) .
Secure the two plugs of the wiring harness to the engine speed/timing sensors in the timing gear housing. Use new straps to hold the wiring harness to the side covers of the cylinder block.End By:
Install the electronic control module (ECM). Refer to Disassembly and Assembly, "Electronic Control Module - Remove and Install".
Install the rocker arms and pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install".
Install the unit injector hydraulic pump. Refer to Disassembly and Assembly, "Unit Injector Hydraulic Pump - Install".
Install the auxiliary water pump. Refer to Disassembly and Assembly, "Auxiliary Water Pump - Install".
Install the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Install".