840842 Volvo.Penta Distribution pipe

Start By:a. remove exhaust manifoldsb. remove air inlet manifoldc. remove rocker shaft and push rodsd. remove fuel injection nozzles1. Remove the coolant from the cooling system. 2. Remove clamps (2) from the water sleeves in each cylinder head. Push water sleeves (1) into the timing gear cover with tool (A).3. Remove the firewall (right head only). 4. Remove the bolts that hold alternator bracket (5) and brace (6) to the cylinder head (right head only).5. Disconnect wiring (3) and remove fuel lines (4) (right head only). 6. Remove bolts (7) and (9) that hold the cylinder heads to the cylinder block. Bolt (10) (left head only) must be removed with the cylinder head as a unit. The bolt can not be removed while the head is in place on the cylinder block.
Make sure the fuel injection nozzles are removed before removing the cylinder heads. The fuel injection nozzles go through the cylinder head and the nozzle tips can be broken off if the nozzles are not removed from the heads.
7. Install two 5/16" - 18 NC forged eyebolts in each cylinder head. Fasten a hoist and remove cylinder heads (8). The weight of each cylinder head is 39 kg (85 lb.).Install Cylinder Head
1. Clean the contact surfaces of each cylinder head and the cylinder block. Make sure the surfaces are clean and dry. Install a new gasket for each cylinder head. Clean the bore in each cylinder head for the water sleeves. Put oil on the seals on the water sleeves. 2. Install two 5/16" - 18 NC forged eyebolts in each cylinder head. Fasten a hoist and put cylinder heads (2) in position on the cylinder block. Make sure bolt (1) is installed in the cylinder head (left head only) before installing the cylinder head. 3. Put clean engine oil on the bolt threads and install the bolts that hold the cylinder heads in place. Tighten the bolts in each cylinder head as follows: 4. Push the water sleeves into the cylinder heads with tool (A). Install the clamps on the water sleeves.5. Connect the wiring to the oil pressure switch (right head only). 6. Install the fuel lines that go to the fuel transfer pump and tube (3) (right head only).7. Install the bolts that hold the alternator bracket and brace to the head (right head only). Install the firewall (right head only).8. Fill the cooling system with coolant to the correct level.End By:a. install fuel injection nozzlesb. install rocker shafts and push rodsc. install air inlet manifoldd. install exhaust manifoldsDisassemble Cylinder Head
Start By:a. remove cylinder heads 1. Fasten a hoist and put the cylinder head in position on tool (A). Use adapter plates (1) from tooling (A) to hold the head in place. 2. Put tension on the valve springs with tool (C) and remove the locks.3. Remove tool (C), retainer, springs, washer, and valve from the cylinder head. Put identification on the valve as to its location in the cylinder head. 4. Check the spring force with tool (B). For correct spring force, see the topic, Valves, in Specifications.5. Do Steps 2 through 4 again for the remainder of the valves. 6. Remove the exhaust valve seat inserts with tooling (D). The valve guides are part of the cylinder head. Measure the bore in each valve guide 19.0 mm (.75 in.) from the outside edge on both ends of each valve guide. The bore must be 9.512 0.013 mm (.3745 .0005 in.). The maximum permissible bore is 9.550 mm (.3760 in.). Valve guides worn more than the maximum specification can be made to the original size by knurling.Assemble Cylinder Head Assemblies
1. Clean and remove burrs and all foreign material from the valve seat bores.
Do not make the diameter of the extractor [part of tooling (A)] in valve seat insert larger when the insert is installed in the cylinder head.
2. Lower the temperature of the valve seat inserts, and install them with tooling (A).3. Grind the valve inserts according to the dimensions given in Specifications. 4. Put clean engine oil on the valve stem. Install the valve, washer (3), springs (2) and retainer (1) in the cylinder head. 5. Put the valve springs under compression with tool (C).6. Install the locks on the valve stem with tool (B).
Make sure locks (4) are in their correct position on the valve. The locks can be thrown from the valve when tool (C) is released if the locks are not in their correct position on the valve.
7. Remove tool (C), and hit the valve with a rubber hammer to be sure the locks are in their correct position.8. Do Steps 4 through 7 for the remainder of the valves.End By:a. install cylinder head assemblies