857405 Volvo.Penta Base engine

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Guide Bolt
M16 by 115mm 2
B - Straight Edge 1
C 8T-3052 Degree Wheel 1
D 1U-6396 O-ring Assembly Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Thoroughly clean the faces of the cylinder head and the cylinder block. Do not damage the faces of the cylinder head or the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.
Inspect the face of the cylinder head for distortion. Refer to Specifications, "Cylinder Head" for more information. If the face of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head.
Illustration 1 g01763193
Inspect dowels (18) for damage. If necessary, replace the dowels in the cylinder block.
Install Tooling (A) to the cylinder block. Refer to Illustration 1.
Align cylinder head gasket (19) with Tooling (A) and with dowels (18). Install the cylinder head gasket onto the cylinder block.
Use a suitable lifting device to lift the cylinder head. The weight of the cylinder head is approximately 56 kg (124 lb).
Use Tooling (A) to align cylinder head (17) with the cylinder block. Install the cylinder head to the cylinder block. Note: Ensure that the cylinder head is correctly positioned onto dowels (18).
Illustration 2 g01250784
Clean bolts (16). Follow Step 8.a and Step 8.b for the procedure to inspect the bolts.
Check the length of the bolts.
Use Tooling (B) in order to check the threads of the bolts. Refer to Illustration 2. Replace any bolts that show visual reduction in the diameter of the thread over length (Y).
Lubricate the threads and the shoulder of bolts (16) with clean engine oil.
Remove Tooling (A).
Illustration 3 g01245538
Illustration 4 g01476553
Sequence for tightening the bolts for the cylinder head
Install bolts (16) to cylinder head (17).
Tighten bolts (16) to a torque of 50 N m (37 lb ft) in the sequence that is shown in Illustration 4.
Tighten bolts (16) to a torque of 100 N m (74 lb ft) in the sequence that is shown in Illustration 4.
Use Tooling (C) to turn bolts (16) through an additional 225 degrees. Turn bolts (16) in the sequence that is shown in Illustration 4.
Illustration 5 g01476537
Typical example
Install new O-ring seal (14) and O-ring seal (15) to bypass tube (13). Use Tooling (D) in order to lubricate O-ring seal (14). Install the bypass tube to the cylinder head. Install bolts (12). Tighten the bolts to a torque of 22 N m (16 lb ft). Note: Ensure that any brackets that are secured by the bolts are installed in the correct position.
Illustration 6 g01249479
Typical example
If the engine is equipped with a wastegate solenoid, install tube assembly (9) to the wastegate solenoid and to the cylinder head. Install the bolts for tube clip (10) and tube clip (11). Tighten M8 bolts to a torque of 22 N m (16 lb ft). Tighten M10 bolts to a torque of 44 N m (32 lb ft). Secure harness assembly (9) to tube assembly (8).
Illustration 7 g01249474
Typical example
Follow Step 17.a through Step 17.c in order to install tube assembly (6) for the fuel return.
Install the banjo bolts and new sealing washers to tube assembly (6).
Install tube assembly (6) to the cylinder head and to transfer pump (7).
Tighten the banjo bolts to a torque of 21 N m (15 lb ft).
If necessary, install the electronic sensors to the cylinder head. Refer to Disassembly and Assembly, "Coolant Temperature Sensor - Remove and Install". Refer to Disassembly and Assembly, "Air Temperature Sensor - Remove and Install". Refer to Disassembly and Assembly, "Boost Pressure Sensor - Remove and Install".
Illustration 8 g01763173
Typical example