240538 Volvo.Penta Connecting kit

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Guide Studs
M16 by 140mm 2
B 21825607 Degree Wheel 1
C - Delphi Lockheed Rubber Grease 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.
Thoroughly clean the gasket surfaces of the cylinder head and the cylinder block. Do not damage the gasket surfaces 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 gasket surface of the cylinder head for distortion. Refer to Specifications, "Cylinder Head" for more information. If the gasket surface of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head.
Illustration 1 g06483294
Inspect dowels (4) for damage. If necessary, replace the dowels (4) in the cylinder block.
Install Tooling (A) to the cylinder block (6).
Align cylinder head gasket (5) with dowels (4). Install cylinder head gasket (5) onto the cylinder block.
Use a suitable lifting device to lift cylinder head. The weight of the cylinder head is approximately 50 kg (110 lb).Note: A spreader bar must be used to distribute the weight of the cylinder head during the lifting operation.
Use Tooling (A) to align the cylinder head with the cylinder block. Install the cylinder head to the cylinder block.Note: Ensure that the cylinder head is correctly positioned on dowels (7).
Remove Tooling (A).
Illustration 2 g06483297
Clean bolts (2). Use a straight edge 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 shoulders of bolts (5) with clean engine oil.
Illustration 3 g06483278
Illustration 4 g06358708
Install bolts (2) to cylinder head (3).
Tighten the bolts to a torque of 50 N m (37 lb ft) in the numerical sequence. Refer to Illustration 4.
Tighten the bolts to a torque of 100 N m (74 lb ft) in the numerical sequence. Refer to Illustration 4.
Use Tooling (B) to turn the bolts through an additional 250 degrees in the numerical sequence. Refer to Illustration 4.
Reconnect the inlet manifold temp and pressure sensor. Refer to Disassembly and Assembly, Inlet Manifold Temperature and Pressure Sensor - Remove and Install for the correct procedure.
Reconnect the EGR temperature sensor to Disassembly and Assembly, Temperature Sensor (Cooled Exhaust Gas) - Remove and Install for the correct procedure.
Reconnect the coolant temperature sensor. Refer to Disassembly and Assembly, Coolant Temperature Sensor - Remove and Install for the correct procedure.
Position the harness assembly onto the cylinder head. Use new cable straps to secure the harness assembly to the cylinder head. Ensure that cable straps meet the OEM specification. Ensure that the harness assembly is not strained.Note: Ensure that the harness assembly is positioned correctly and clear of other engine components.
Illustration 5 g06357254
If necessary, install water temperature regulator housing (1) to the cylinder head. Refer to Disassembly and Assembly, "Water Temperature Regulator Housing - Remove and Install" for the correct procedure.
Connect the upper radiator hose to water temperature regulator housing (1) on the cylinder head.End By:
Install the rocker shaft and pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install" for the correct procedure.
Install the glow plugs. Refer to Disassembly and Assembly, "Glow Plugs - Remove and Install" for the correct procedure.
Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Install" for the correct procedure.
Install the fuel manifold. Refer to Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install" for the correct procedure.
Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install" for the correct procedure.
Fill the cooling system. Refer to Operation and Maintenance Manual, "Coolant - Change" for the correct procedure.
If necessary, Fill the engine oil pan to the correct level. Refer to Operation and Maintenance Manual, "Engine Oil Level - Check," for the correct procedure.