856138 Volvo.Penta Carburettor

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Loctite Graphite 50 -
B 8T-2998 Lubricant -
C 9S-3263 Thread Lock Compound -
D 4C-9505 Gasket Sealant -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01239785
Install O-ring seal (20) on the dowel in the cylinder block.
Install spacer plate gasket (22) on the cylinder block. Install spacer plate gasket (22) with the following procedure.Note: Thoroughly clean the spacer plate, the bottom surface of the cylinder head, and the top surface of the cylinder block. A new spacer plate gasket and a cylinder head gasket must be installed when the cylinder head is removed.Note: Apply a thin film of clean engine oil on the O-ring seals prior to installation.
For best results, clean all surfaces and dry all surfaces with a solvent that is free of residue.
Apply Tooling (D) as a uniform film to the bottom side of spacer plate gasket (22). Position spacer plate gasket (22).
Apply Tooling (D) as a uniform film to the top side of spacer plate gasket (22). Formulas that dry more slowly increase the time for the procedure.
Once the repairs are completed and the sealant has had adequate time to cure, the engine can be run.
If necessary, Tooling (D) can be removed from metal surfaces with isopropyl alcohol.
Install seals (23) and seal (21).
Install spacer plate (19).
Install cylinder head gasket (18) on the spacer plate.
Illustration 2 g01239779
Attach a suitable lifting device to cylinder head (14). The weight of cylinder head (14) is approximately 235 kg (518 lb).
Carefully install cylinder head (14) on the dowel pins on the cylinder block.
Apply Tooling (A) to the threads of cylinder head bolts (17) and both sides of the washers. Install cylinder head bolts (17).
Illustration 3 g01072801Note: The bolts that are Marked "X" are 216 mm (8.5 inch) long: 11, 12, 13, 14, 16, 18, 20, 22, 24 and 26. The rest of the bolts are 194 mm (7.6 inch) long.
Tighten the cylinder head bolts according to the following procedure.
In a numerical sequence, tighten Bolt (1) through Bolt (26) to a torque of 270 15 N m (200 11 lb ft).
In a numerical sequence, tighten Bolt (1) through Bolt (26) to a torque of 450 15 N m (330 11 lb ft).
In a numerical sequence, again tighten Bolt (1) through Bolt (26) to a torque of 450 15 N m (330 11 lb ft).
Illustration 4 g01239627
Position the gasket and air inlet elbow (10) on cylinder head (14) and install bolts (11).
Connect hose assembly (16) at cylinder head (14).
Connect tube assembly (15).
Connect hose assembly (8) at cylinder head (14). Install the bolt and the clip that secures the hose assembly to the front housing. Install the bolt and the clip that secures the hose assembly to the cylinder head.
Position the breather tube on cylinder head (14) and install bolt (13). Tighten bolt (13) to a torque of 10 3 N m (89 27 lb in).
Position the bracket on cylinder head (14) and install bolts (7).
Connect harness assemblies (12) and (9).
Illustration 5 g01067192
Install O-ring seal (5) and O-ring seal (6) on sealing plate (3). Lubricate O-ring seal (6) with a 50/50 mixture of Tooling (B) and clean engine oil.
Illustration 6 g01067193
Illustration 7 g01067195
Install adapter assembly (4) and sealing plate (3). Ensure that the dowel in adapter assembly (4) engages the hole in the camshaft.Note: Ensure that the O-ring seal stays in the groove in sealing plate (3).
Install thrust plate (1). Apply Tooling (C) to bolts (2). Hold the thrust plate in position and install bolts (2). Evenly tighten bolts (2) until sealing plate (3) and the O-ring seal are seated against the cylinder head.End By:
Install the water temperature regulator. Refer to Disassembly and Assembly, "Water Temperature Regulator - Remove and Install".
Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".
Install the valve mechanism cover base. Refer to Disassembly and Assembly, "Valve Mechanism Cover Base - Remove and Install".
Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Install".
Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install".