3840818 Volvo.Penta Cylinder liner kit

1. Remove fuel lines (1). Put caps on all fuel line openings. 2. Disconnect all tubing (2). 3. Remove the bolts (3) that hold bracket to air cleaner housing. 4. Remove the nuts from studs that hold bracket. Remove bracket (5) and gasket (4). 5. Remove the bolts (6) that hold camshaft housings to the cylinder heads.6. Fasten tooling (A) to the camshaft housings along with a hoist. Remove bolts (8) and then remove camshaft housings (7). Weight of the camshaft housing is 150 lb. (68 kg). Install Camshaft Housings
1. Clean and inspect all parts. Make a replacement of all parts that are worn or damaged.2. Adjust all valve adjustment screws for maximum valve clearance. 3. Put the timing marks on the drive gear (3) for the camshaft in alignment and install timing pin (4) in the camshaft.4. Check to be sure that the crankshaft is at top center compression stroke for No. 1 piston and the timing bolt is installed in the flywheel.
If above procedure in Steps 1 to 3 are not followed, damage to the engine can be the result.
5. Put gasket (2) in position. Fasten tooling (A) and a hoist then put camshaft housing (1) in position on the engine. Make sure the camshaft gear teeth are engaged in the teeth of the drive gear. Install the bolts (5) that hold the camshaft housing in position. 6. Install bracket (6) and the gasket on camshaft housing with the nuts and bolts (7) that hold it. 7. Install all tubing (8). 8. Install fuel lines (9). Tighten the nuts to a torque of 30 5 lb.ft. (40 7 N m).end by:a) install valve coversb) install fuel linesDisassemble Camshaft Housing
start by:a) remove camshaft housings 1. Remove bolts and locks (1) and remove fuel line adapters (2) from the camshaft housing. 2. Bend the locks away from bolts (3) and remove the bolts. Remove the pointer from the housing. 3. Bend the locks away from bolts (4). Remove the bolts and thrust plate (5). 4. Remove plates (6) and (7) from the camshaft housing.5. Carefully remove camshafts (8) from the housing. 6. Remove the camshaft gears from the housing. 7. Remove bolts (9) that hold the rocker shafts in place.8. Remove the rocker shafts and rocker arms (11).9. Remove guide pins (10) from the bottom side of the housing. 10. Remove dowel (14), pin (12) and roller (13) from the rocker arms.11. Remove screw assemblies (17), plungers (16) and springs (15).Assemble Camshaft Housing
1. Clean and inspect all parts. Make a replacement of the parts that are worn or damaged. 2. Put roller (2) in position and install pin (1) and dowel (3) in the rocker arm to hold the roller in place. Install the dowel from the top of the rocker arms.3. Install springs (4), plungers (5) and screw assemblies (6) in the rocker arms.4. Install guide pins (7) in the housing from the top. 5. Install rocker arms (8) and shafts (9). 6. Install bolts (10) and the locks that hold the shafts in place.7. Put camshafts (11) in position in the housing. The shaft with the hole for the timing pin is the inlet camshaft. The shaft with the identification "EX" on it is the exhaust. 8. Install thrust plate (12) and the bolts that hold it in place. The end clearance for either camshaft is .004 to .010 in. (0.10 to 0.25 mm). 9. Install the gears on the camshafts with the "V" mark on the tooth of the thick gear in alignment with the "V" mark in the space on the thin gear. On the right camshaft housing install the thick gear on the exhaust camshaft. On the left camshaft housing install the thick gear on the intake camshaft. 10. Install pointer (14) in the housing toward the thin gear as shown. The pointer must be in alignment with the mark on the thin gear when timing pin (13) is installed. 11. Install the locks and bolts (16) that hold the gears in place on the camshafts.12. Put 8M8058 Loctite on tees (15) (if removed). Install the tees in the camshaft housing. 13. Install plates (17) and (18) on the camshaft housing.14. Install the fuel line adapters.end by:a) install camshaft housings