876624 Volvo.Penta Gasket kit

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     149-2955     Seal Protector     1    
B     149-2956     Seal Installer     1    
C     367-3070     Fuel Injector Installer and Removal Tooling     2    
D     1U-5718     Vacuum Pump     1    
169-7372 Bottle Assembly     1    
4C-4057 Clear Plastic Tubing
7.92 mm (0.312 inch) OD     1    
4C-4055 Clear Plastic Tubing
6.35 mm (0.250 inch) OD     1    
E     9U-5470     Reamer     1    
F     4C-6161     Tube Brush     1    
G     9U-6862     Tapered Brush     1    
H     4C-6774     Vacuum Gun Kit     1    
J     4C-5027     Tap Wrench     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Evacuate as much fuel and oil as possible from the cylinder head before installing the unit injector. Several evacuations may be necessary. Use Tooling (D) to remove the fuel and oil from the cylinder head.Note: Tooling (H) is available to clean loose material from the sleeve bore and the cylinder.
Inspect the unit injector sleeve for damage. If the unit injector sleeve is worn or damaged use a new part for replacement.
Inspect the bores for the unit injector and the seating surfaces for the unit injector for carbon deposits.
Clean the carbon from the sleeve, the sleeve bore, and the end of the unit injector, if the unit injector is being reused. Clean the carbon from the seat area that is inside of the cylinder head. A fine grade of Scotch Brite material is preferred. Scotch Brite is available from the Tools And Shop Products Guide. Use Tooling (E) to clean the injector tip bore. Use the Surface Reconditioning Pad in order to clean the carbon in the cylinder head. Use Tooling (F) in order to remove the carbon from the surface of the sleeve.Note: Using power tools in order to rotate the material should not be necessary. The carbon in the sleeve is more removable than the carbon at locations that are exposed to higher temperatures.The following procedure is the preferred method of cleaning the sleeve bore.Place a 38 mm (1.5 inch) square piece of Scotch Brite material on the end of Tooling (G) . Twist Tooling (G) with Tooling (J) against the lower surface of the sleeve bore.The surface should be cleaned until the surface is smooth and shiny. The entire sleeve bore should be cleaned in order to remove any loose carbon particles.Note: Tooling (H) is available to clean loose material from the sleeve bore and the cylinder.
The correct procedures and tooling specifications must always be used. Failure to follow any of the procedures may result in damage, malfunction, or possible engine failure.
Illustration 1 g00947495
Front oil gallery plug
Illustration 2 g00947501
Rear oil gallery plug
Install the oil drain plugs (1) and (2) . Torque the drain plugs to the following torque 290 25 N m (214 18 lb ft).
Illustration 3 g00947503
Install injection actuation pressure sensor (3) . Torque the sensor to 10 2 N m (88 18 lb in).Note: New seals should be installed after each removal of the unit injector from the engine. To order O-ring seals for the unit injector, refer to the Parts Manual.
The O-ring seals and the backup rings must be installed in the correct orientation. Damaged seals will result in excessive oil consumption or excessive leakage under the valve cover. Use care to prevent nicks or damage to the seals.
Illustration 4 g00949104
Lubricate O-ring seals (10) , (11) , and (12) and the sleeve bore of the injector sparingly with clean engine oil.
Use Tooling (A) to install backup rings (8) and (9) first. Use Tooling (B) to install O-ring seal (10) .
Use Tooling (A) to install backup ring (13) . Use Tooling (B) to install O-ring seal (12) .
Use Tooling (B) to install O-ring seal (11) .
Lubricate the O-ring seals and the backup rings on the unit injector