20790423 Volvo.Penta Big-end bearing kit

Table 1
Required Tools
Tool Part Number Part Description Qty
A 6V-6640 Sealant -
B - Guide Stud
(M16 x 2.0 x 200 mm) 2
C 8T-3052 Degree Wheel 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01141531
Apply Tooling (A) to cup plugs (15). Install the cup plugs in the cylinder head.
Install pipe plugs (15) in the cylinder head.
Install the O-rings on plug assemblies (13) and plug assemblies (14). Install the plug assemblies in the cylinder head.
Thoroughly clean the mating surfaces of the cylinder head and the cylinder block.
Install Tooling (B) in the cylinder block.
Install a new cylinder head gasket assembly on the cylinder block.
Illustration 2 g01140918
Attach a suitable lifting device to cylinder head (10). The weight of cylinder head (10) is approximately 104 kg (228 lb). Position the cylinder head on Tooling (B).
Apply clean engine oil to the threads of cylinder head bolts (11) and under the bolt head. Install cylinder head bolts (11). Remove Tooling (B). Install the remaining cylinder head bolts.
Illustration 3 g01140758
Tighten the cylinder head bolts according to the following procedure:
In a numerical sequence, tighten bolts 1 through 26 to a torque of 130 15 N m (96 11 lb ft).
In a numerical sequence, tighten bolts 1 through 26 to a torque of 130 15 N m (96 11 lb ft).
In a numerical sequence, tighten bolts 1 through 26 for an additional 90 5 degrees (1/4 turn). Note: If Tooling (C) is not used, place an index mark on the bolt and the cylinder head.
Completely loosen bolts 1 through 26.
In a numerical sequence, tighten bolts 1 through 26 to a torque of 130 15 N m (96 11 lb ft).
In a numerical sequence, tighten bolts 1 through 26 to a torque of 130 15 N m (96 11 lb ft).
In a numerical sequence, tighten bolts 1 through 26 for an additional 90 5 degrees (1/4 turn). Note: If Tooling (C) is not used, place an index mark on the bolt and the cylinder head.
In a numerical sequence, tighten bolts 27 through 31 to a torque of 28 75 N m (20 5 lb ft).
Illustration 4 g01027265
Install tube assembly (9) to cylinder head (10).
Illustration 5 g01027299
Connect harness assembly (7) and harness assembly (8) for the oil temperature sensors.
Install air inlet heater relay (5).
Connect injection actuation pressure sensor (6).
Illustration 6 g00976251
Connect fuel return tube assembly (4).
Connect inlet air pressure sensor (2).
Connect inlet air temperature sensor (3).
Connect coolant temperature sensor (1). End By:
Install the alternator. Refer to Disassembly and Assembly, "Alternator - Remove and Install".
Install the oil filter base. Refer to Disassembly and Assembly, "Oil Filter Base - Remove and Install".
Install the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install".
Install the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Install".
Install the heat exchanger. Refer to Disassembly and Assembly, "Heat Exchanger - Install".
Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install".
Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".
Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Install".
Install the rocker arm and shaft. Refer to Disassembly and Assembly, " Rocker Arm and Shaft - Remove and Install".
Install the valve cover base. Refer to Disassembly and Assembly, " Valve Mechanism Cover Base - Remove and Install".