471528 Volvo.Penta Gear, crankshaft

2. Remove radiator top tank lines (2) from each side of the engine.3. Remove water temperature regulator housings (5).4. Do Steps 4a through 4d for the right hand cylinder head only. a) Disconnect the heater hose from fitting (8).b) Disconnect wire assembly (7) from the sensor unit.c) Disconnect air line (3) from the cylinder head.d) Disconnect fuel lines (4) from lines (6). Put protection caps on all fuel line openings.5. Remove valve covers (1). 6. Disconnect glow plug wires (12) from the glow plugs. Disconnect the clips for glow plug wires (12) from fuel lines (11).7. Disconnect glow plug wires (10) from valve cover base (13).8. Disconnect fuel lines (9) from valve cover base (13). Put protection caps on all fuel line openings.9. Use tool (A) and remove fuel lines (11).10. Remove the bolts and remove valve cover base (13). 11. Loosen bolts (14) evenly and remove rocker shaft assembly (16).12. Remove push rods (15). 13. Put identification on valve bridges (18) for installation purposes. Remove valve bridges (18).14. Remove glow plug wiring harness (17). 15. Remove the bolt from automatic timing advance housing to bracket (19). Remove bracket (19) and bracket (20) Remove remainder of 3/8" head bolts.16. Install three 5/16"-18 NC forged eyebolts in the cylinder head. Fasten a hoist to the cylinder head. 17. Remove cylinder head bolts (21). Remove the cylinder head. Weight of the head is 200 lb. (90.7 kg). A new spacer plate gasket must be installed when the cylinder head is removed. See REMOVE AND INSTALL SPACER PLATE.Install Cylinder Heads
1. Thoroughly clean the spacer plates and bottom surface of the cylinder heads. Install a new head gasket and seals. Do not use any adhesives. A new spacer plate gasket must be installed when the cylinder head is removed. See REMOVE AND INSTALL SPACER PLATE.2. Put the cylinder head into position on the spacer plate. The use of guide bolts will help to put the cylinder head in alignment with the spacer plate.3. Put clean engine oil on the threads of the cylinder head bolts. Install cylinder head bolts and washers. Tighten the bolts in the following sequence. a) Tighten bolts 1 through 14 in number sequence to a torque of 200 20 lb.ft. (270 25 N m).b) Tighten bolts 1 through 14 in number sequence to a torque of 330 15 lb.ft. (447 15 N m).c) Tighten bolts 1 through 14 in number sequence to a torque of 330 15 lb.ft. (447 15 N m). 4. Install glow plug wiring harness (2).5. Put clean engine oil on the bridge dowels. Install valve bridges (1) in their respective locations on the cylinder head.6. Push straight down on the top contact surface of valve bridge (1) with a force of 1 to 10 lb. (4 to 45 N m). Turn the adjustment screw clockwise until contact is made with the valve stem. Turn the adjustment screw 20° to 30° more to keep bridge (2) straight on the dowel. Hold the adjustment screw in this position and tighten the locknut to a torque of 22 3 lb.ft. (28 4 N m).7. Install the push rods. 8. Put rocker shaft assembly (7) in position. Make an alignment of the push rods and rocker arms. Put clean engine oil on the threads of bolts (3) through (6). Install bolts and washers. Tighten the bolts as follows: a) Tighten bolts (3) through (6) in number sequence to a torque of 200 20 lb.ft. (270 25 N m).b) Tighten bolts (3) through (6) in number sequence to a torque of 330 15 lb.ft. (447 15 N m).c) Tighten bolts (3) through (6) in number sequence again to a torque of 330 15 lb.ft. (447 15 N m). 9. Install bracket (12) and spacer (11). Tighten bolts (8) finger tight. Tighten the bolt that holds the automatic timing advance housing to bracket (12) to standard torque. Tighten bolts (8) to a torque of 32 5 lb.ft. (43 7 N m).10. Install bracket (10). Tighten bolts (13) finger tight. Tighten bolts (9) to standard torque. Tighten bolts (13) to a torque of 32 5 lb.ft. (43 7 N m).11. Tighten the remainder of the 3/8" head bolts to a torque of 32 5 lb.ft. (43 7 N m). If the studs for the exhaust manifold were removed, install new studs and tighten them to a torque of 20 3 lb.ft. (25 4 N m).12. Make an adjustment of the valves to have a clearance of .015 in. (0.38 mm) for intake and .030 in. (0.76 mm) for exhaust. See VALVE CLEARANCE SETTING in TESTING AND ADJUSTING. 13. Install the valve cover base on the cylinder head. Tighten the bolts in number sequence shown to a torque of 18 5 lb.ft. (24 7 N m). 14. Put clean engine oil on O-ring seal (15). Install the spacers and fuel line adapters (14). Install locks (16). 15. Connect fuel lines (17) to the fuel line adapters. Tighten the fuel line nuts to a torque of 30 5 lb.ft. (40 7 N m).16. Put clean engine oil on the O-ring seal on fuel lines (18) and connect the fuel lines to the fuel line adapters and precombustion chambers. Tighten the fuel line nuts to a torque of 30 5 lb.ft. (40 7 N m) with tool (A).17. Connect glow plug wires (19) to the glow plugs. Connect the clips for the glow plug wires to fuel lines (18). 18. Install valve covers (20).19. Do Steps 18a through 18d for the right hand cylinder head only.a) Connect heater hose to fitting (27).b) Connect wire assembly (26) to the sensor unit.c) Connect fuel line (22) to the cylinder head.d) Connect fuel lines (23) to fuel lines (25).20. Install water temperature regulator housings (24).21. Install radiator top tank lines (21).22. Fill the cooling system with coolant to