240060 Volvo.Penta Lever

2. Remove bolt (4) from the engine oil cooler. Remove the four bolts (3) that hold clip and fasten turbocharger elbow (1) to the cylinder head.3. Remove water separator mounting bracket (2).4. Remove tube assemblies (6) and (7) from the air compressor to the cylinder head. 5. Loosen hose clamp (8) on the water line inlet elbow. Remove water temperature sending unit (5) from head. 6. Remove four bolts (9) that fasten elbow (10) to the water pump. Slide the elbow forward on the top of the water pump. 7. Remove sixteen bolts (11) and loosen bolts (12) that fasten the cylinder head to the engine block. The back three bolts (12) can not be removed until the cylinder head is removed. Remove bracket from the rear of the cylinder head. 8. Install tooling (A) and a hoist on the cylinder head (13) and remove head and gasket from engine. The weight of the cylinder head is 150 lb. (68 kg). When the cylinder head is removed, a new spacer plate gasket must be installed. See REMOVE AND INSTALL SPACER PLATE.Install Cylinder Head
When the cylinder head is removed, a new spacer plate gasket must be installed. See REMOVE AND INSTALL SPACER PLATE. 1. Clean the surfaces of the cylinder head and the cylinder block that make contact with each other. Make sure the surfaces are clean and dry. Install a new, dry gasket (2) on the cylinder block.2. Fasten a hoist and tooling (A) to cylinder head (1) and put it in position on the cylinder block. The back three cylinder head bolts must be in head before installation.3. Put 2P2506 Anti-Seize Compound on all the head bolts and rocker shaft bolts except bolt (17). Install the head bolts and washers that hold the head in place. Do not tighten bolts at this time. 4. Install push rods (4) and rocker shaft assembly (3). Install the bolts and washers that hold the rocker shaft assembly in place. 5. Tighten the bolts as follows:a) Tighten bolts 1 through 18 in number sequence to a torque of 115 lb.ft. (155 N m).b) Tighten bolts 1 through 18 again in number sequence to a torque of 185 13 lb.ft. (250 17 N m).c) Tighten bolts 1 through 18 again in number sequence (hand tighten only) to a torque of 185 13 lb.ft. (250 17 N m).d) Tighten bolts A through E in letter sequence to a torque of 32 5 lb.ft. (43 7 N m).e) Tighten bolts (hand tighten only) A through E again in letter sequence to a torque of 32 5 lb.ft. (43 7 N m).6. Make adjustments until the intake valve clearance is .015 in. (0.38 mm) and the exhaust valve clearance is .025 in. (64 mm). See ENGINE VALVE LASH as shown in MAINTENANCE GUIDE. Tighten the locknuts for the adjustment screws to a torque of 21 5 lb.ft. (29 7 N m). 7. Inspect the two gaskets (6) for the water pump elbow and make a replacement if necessary. Put elbow (5) in position on water pump and in the water inlet pipe hose.8. Tighten clamp (9) on water inlet hose. 9. Install tube assemblies (7) and (10) from the air compressor to the cylinder head.10. Install temperature sending unit (8). 11. Install bolt (13) that fastens the water separator mounting bracket (12) to the engine oil cooler.12. Inspect the turbocharger elbow gasket and make a replacement if necessary.13. Put the turbocharger elbow (11), fuel separator bracket (12) and the temperature sending unit line bracket in position on the cylinder head and install four mounting bolts. 14. Install bracket (14) in position on the rear of the cylinder head.END BY:a) install exhaust manifoldb) install water temperature regulatorc) install water separator