864621 Volvo.Penta Cap

1 Steam clean the engine. Obtain an SOS sample; be sure the oil is hot and well mixed before you take the sample. Disconnect the batteries.2 Disconnect the hose(s) from the positive crankcase ventilator valve(s). Remove the right valve cover. 3 Remove four bolts (1) that hold the rocker shaft assembly in position. Remove the rocker shaft and bracket. Be sure to install the rocker shaft and bracket assembly on the same side from which they were removed.4 Clean the area around each fuel line connection thoroughly. Disconnect fuel injection line (3) from the adapter. Disconnect fuel injection nozzle (4) from each adapter. Remove clamp (5) and the spacers that hold the fuel injection nozzles in position.
Never use force, such as a prybar, to remove the fuel injection nozzles. If necessary, use 6V4061 Puller Group to remove the nozzles more easily.
5 Remove adapters (6) from the cylinder head. Remove the fuel injection nozzles. Put 2F2990 Plugs and 5F2807 Caps on fuel openings and protect the nozzle tips from damage and dirt entry.6 Remove the left valve cover and the left rocker shaft assembly. Remove the adapters and fuel injection nozzles from the left cylinder head assembly.7 Make sure new seals are on the fuel line adapters and fuel injection nozzles. Use a twisting motion to install the nozzle into its correct position. Never put lubrication on the nozzle or bore in the cylinder head.8 Install the adapters in the cylinder head. Connect the nozzle and fuel injection lines to the adapter. Use 5P0144 Socket to tighten the nuts to a torque of 40 7 N m (30 5 lb.ft.). Install the spacer and clamp that hold each nozzle to the cylinder head.9 Position the rocker shafts on the engine. Install the rocker shaft bolts and tighten them to 24 7 N m (18 5 lb.ft.).10 No. 1 piston at top center (TC) on the compression stroke is the starting point for adjusting valve clearances. Remove the plug from timing hole (8) in the front cover. Put bolt (7) in timing hole (8). The bolt from hole (9) can be used. Turn the crankshaft counterclockwise (as seen from the rear of the engine) until bolt (7) will go into the hole in the drive gear for the camshaft.11 The two valves at the right front of the engine are the intake and exhaust valves for No. 1 cylinder, and must now be closed; the timing pointer will be in alignment with the TC on the damper assembly. The No. 1 piston is now at TC on the compression stroke. 12 Make adjustment to the valves for No. 1 and No. 2 cylinders. To adjust, loosen locknut (11) and turn adjustment screw (10) until feeler gauge (12) will go between the end of the valve stem and the rocker arm.13 After the adjustment is made, hold adjustment screw (10) and tighten locknut (11) to 32 7 N m (24 5 lb.ft.). Check the adjustment again.14 Turn the crankshaft counterclockwise (as seen from the rear of the engine) 180°. The "VS" mark on the damper assembly will be in alignment with the timing pointer. Make adjustment to the valves for No. 3 and No 7 cylinders.15 Turn the crankshaft counterclockwise (as seen from the rear of the engine) 180°. The TC mark on the damper assembly will be in alignment with the timing pointer. Make adjustment to the valves for No. 4 and No. 5 cylinders.16 Turn the crankshaft counterclockwise (as seen from the rear of the engine) 180°. The "VS" mark on the damper assembly will be in alignment with the timing pointer. Make adjustment to the valves for No. 6 and No. 8 cylinders.17 Remove the screws that hold the crankcase ventilation valve(s) to the valve cover(s). Remove cover (13) and the spring from the housing. Remove piston (17), sleeve (14), retainer (19) and diaphragm (18) from the housing as a unit. Remove inner sleeve (14) and gasket (15). Remove the nut, washer, spacer, piston, diaphragm and retainer from sleeve (20).18 Clean the inner sleeve in clean, non-flammable solvent and shake or blow dry it. Put gasket cement on both sides of gasket (15) and install it. Install inner sleeve (14). Put the piston next to the side of diaphragm (18) that reads "PISTON SIDE". Put retainer (19) in the diaphragm. Place the screw through sleeve (20), the retainer, diaphragm and piston. 19 Install the spacer and the nut on the screw. Put gasket cement on the contact surfaces of the diaphragm. Install the sleeve, retainer and piston in the inner sleeve and housing. Put the spring and the cover in position. Install the screws that hold the cover in place.20 Install the new valve cover gasket. Put the valve covers in position on the cylinder heads. Install the valve cover bolts and tighten them, in the sequence shown, to 14 3 N m (10 2 lb.ft.).21 Connect the hose(s) to the crankcase ventilation valve(s). Close the fuel supply valve, if so equipped. Depress the extended tab of the water separator with the heel of the hand. Lift the slotted tab from the locking slot at the top of the base. 22 Pull old element (21) from base (23) and discard. Clean three sealing surfaces (22) with a clean cloth. Install the new element by first inserting roll pin (24) into the passage at the bottom of the base. Align the filter holes with the base holes and push the element into place. Replace the clamp on the element. Make sure the clamp is securely engaged.23 Drain the coolant from the cooling system. Loosen the hose clamps. Remove oil cooler hoses (25) and (26). Install the new oil cooler hoses and tighten the clamps.24 Fill the cooling system to the correct level. Open the fuel valve. Connect the batteries and start the engine. It may be necessary to prime the fuel system if the engine does not start.25 Inspect for leaks.