859197 Volvo.Penta Bushing kit

1. Remove bolts (4) and (3), then remove heat shield (2) and oil filter base bracket (1). 2. Loosen bolt (8) in automatic timing advance unit enough so it is free of bracket (7). Remove two bolts (6) and bracket (7).3. Remove one bolt (5) from fuel injection pump housing. Remove two bolts (9) and bracket (10). 4. Remove bolts (11) to remove rocker shaft assembly (12) and the push rods form the cylinder head.5. Remove valve bridges (13) from the bridge dowels. 6. Fasten straps and a hoist to the air cleaner. Remove bolts (15) that hold air cleaner to the bracket. Remove air cleaner (14). Weight of the air cleaner is 45 kg (100 lb).7. Remove bolt (16), then remove fuel filter bracket (17). 8. Remove two bolts (19), then remove two plates (18). Remove seal. 9. Remove all the bolts from the cylinder head and fasten a hoist to it with tooling (A). Remove cylinder head (20) and a gasket. The weight of the cylinder head is 136 kg (300 lb).Install Cylinder Heads
Make sure a new gasket has been installed between the spacer plate and cylinder block. See REMOVE AND INSTALL SPACER PLATES. 1. Thoroughly clean spacer plate (2) and the bottom surface of the cylinder head. Install a new cylinder head gasket (1) and water seals (3). Do not use any adhesives. 2. Fasten tooling (A) and a hoist to the cylinder head (4). Put the cylinder head in position over the spacer plate and make an alignment of the holes in cylinder head with the dowel pins. Lower the cylinder head on to the spacer plate. Be careful not to cause damage to water seals and cylinder head gasket. 3. Put clean engine oil on all bolt threads and tighten the bolts in the following sequence:a) Tighten bolts 1 through 20 in number sequence to a torque of 270 25 N m (200 20 lb ft).b) Tighten bolts 1 through 20 in number sequence to a torque of 447 20 N m (330 15 lb ft).c) Tighten bolts 1 through 20 in number sequence again to a torque of 447 20 N m (330 15 lb ft). 4. Install valve bridges (5) in their respective positions. Install push rods.5. Install the rocker shaft assemblies on the cylinder head. Put clean engine oil on all bolt threads and tighten the bolts in the following sequence:a) Tighten bolts 21 through 26 in number sequence to a torque of 270 25 N m (200 20 lb ft).b) Tighten bolts 21 through 26 in number sequence to a torque of 447 20 N m (330 15 lb ft).c) Tighten bolts 21 through 26 in number sequence again to a torque of 447 20 N m (330 15 lb ft).6. Install the 3/8" -16 NC bolts in the cylinder head and tighten to a torque of 43 7 N m (32 5 lb ft).7. Check bridge adjustment. See BRIDGE ADJUSTMENT in TESTING AND ADJUSTING.8. Make an adjustment of the valves to have a clearance of 0.38 mm (.015 in) for intake and 0.76 mm (.030 in) for exhaust. See VALVE CLEARANCE SETTING in TESTING AND ADJUSTING. 9. Install two brackets (8) and (9) and thirteen bolts (6). Tighten bolts (6) to a torque of 43 7 N m (32 5 lb ft). Install bolt (7) that holds bracket (8) to the fuel injection pump housing. Install the bolt that holds bracket (9) to the automatic timing advance housing. 10. Install a new O-ring seal (11) on bracket (10). Put bracket (10) in position on the cylinder head and install the bolts that hold it. 11. Fasten straps and a hoist to the air cleaner (12). Put the air cleaner in position on support (13) and bracket (10). Install the bolts that hold it. 12. Install fuel filter housing bracket (16) on air cleaner bracket. Install hoses (14) with bolt (15) that holds them to bracket (16). Remove straps and hoist from air cleaner. 13. Install oil filter base bracket (18) on the cylinder head with the four bolts (19) that hold it.14. Install heat shield (17) on oil filter base bracket with the bolts (20) that hold it.END BY:a) install fuel filters and baseb) install oil filters and basec) install exhaust manifoldsd) install valve cover basese) install water temperature regulatorsf) install coolant filter and conditioner