3803551 Volvo.Penta Cylinder head

Table 1
Required Tools
Tool Part Number Part Name Qty
A 230-6284 Timing Pin (Camshaft) 1
B 230-6283 Timing Pin (Crankshaft) 1
C 9U-6198 Crankshaft Turning Tool 1
D 1U-6396 O-Ring Assembly Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Use Tooling (C) to ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, "Fuel Injection Timing - Check". Note: Install Tooling (A) through the camshaft gear. Install Tooling (B) through the crankshaft web.
Illustration 1 g00956267
Use Tooling (D) in order to lubricate O-ring seal (10). Install a new O-ring seal (10) onto the fuel injection pump.
Install new washers to bolts (13).
Align the holes in the fuel injection pump with the holes in the front housing. Install the fuel injection pump to the housing. Note: The fuel injection pump should be supported by hand until the bolts are installed.
Install bolts (13). Tighten bolts (13) to a torque of 22 N m (16 lb ft).
Position support bracket (11) onto the cylinder block. Install bolt (15) finger tight.
Install bolt (12) and nut (14) finger tight.
Tighten bolt (12) and nut (14) to a torque of 22 N m (16 lb ft). Tighten bolt (15) to a torque of 44 N m (32 lb ft). Note: Ensure that the fuel injection pump is not stressed as the bolts for the bracket are tightened.
Illustration 2 g00956200Note: Ensure that the mating surfaces of the fuel injection pump gear and the shaft of the fuel injection pump are clean. Lubricate the threads of the shaft for the fuel injection pump. The nut must turn freely until contact is made with the fuel injection pump gear.
Position fuel injection pump gear (9) on the shaft of the fuel injection pump. Install the washer and nut (8). Rotate the fuel injection pump gear in a counterclockwise direction in order to remove the backlash. Tighten nut (8) to a torque of 24 N m (17 lb ft).
Illustration 3 g00956204
Connect the harness assembly to timing advance solenoid (7).
Connect harness assembly (2). Connect fuel line (3).
Connect fuel return line (1). Connect tube assembly (4) to the fuel injection pump.
Loosen bolt (5). Move spacer (6) in order to prevent bolt (5) from tightening against the shaft of the fuel injection pump. Tighten bolt (5) to a torque of 12 N m (106 lb in). Note: Spacer (6) must be correctly positioned and bolt (5) must be tightened in order to prevent the bolt from contacting the shaft of the fuel injection pump.
Illustration 4 g00992965
Tighten nut (8) to a torque of 88 N m (65 lb ft).
Remove Tooling (A) and Tooling (B). End By:
Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install".
Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley - Remove and Install".
Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".
Install the air compressor, if equipped. Refer to Disassembly and Assembly, "Air Compressor - Remove and Install".