21482405 Volvo.Penta Pipe end

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Guide Studs
M16 by 140mm 2
B 8T-3052 Degree Wheel 1
C - Delphi Lockheed Rubber Grease 1
D 499-0473 Lifting eye 1
E - Bolt M10 x 1.5 x 25mm 2
F - Bolt M12 x 1.75 x 25mm 2
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.
Thoroughly clean the gasket surfaces of the cylinder head and the cylinder block. Do not damage the gasket surfaces of the cylinder head or the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.
Inspect the gasket surface of the cylinder head for distortion. Refer to Specifications, "Cylinder Head" for more information. If the gasket surface of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head.
Illustration 1 g06358801
Inspect dowels (7) for damage. If necessary, replace the dowels in the cylinder block.
Install Tooling (A) to the cylinder block (9).
Align new cylinder head gasket (8) with dowels (7). Install new cylinder head gasket (8) onto the cylinder block.
Use a suitable lifting device to lift cylinder head. The weight of the cylinder head is approximately 50 kg (110 lb).Note: A spreader bar must be used to evenly distribute the weight of the cylinder head during the lifting operation.
Use Tooling (A) to align the cylinder head with the cylinder block. Install the cylinder head to the cylinder block.Note: Ensure that the cylinder head is correctly positioned on dowels (7).
Remove Tooling (A).
Illustration 2 g06386875
Clean bolts (5). Use a straight edge to check the threads of the bolts. Refer to Illustration 2. Replace any bolts that show visual reduction in the diameter of the thread over Length (Y).
Lubricate the threads and the shoulder of bolts (5) with clean engine oil.
Illustration 3 g06358393
Illustration 4 g06358708
Install bolts (5) to cylinder head (6).
Tighten bolts (5) to a torque of 50 N m (37 lb ft) in the numerical sequence. Refer to Illustration 4.
Tighten bolts (5) to a torque of 100 N m (74 lb ft) in the numerical sequence. Refer to Illustration 4.
Use Tooling (B) to turn bolts (5) through an additional 250 degrees in the numerical sequence shown in Illustration 4.
Illustration 5 g06492861
Remove Tooling (D) and (E) from the cylinder head.
Illustration 6 g06492856
Remove Tooling (F) from lifting eye (2). Remove lifting eye (2) from cylinder head (6).
Illustration 7 g06492852
Install lifting eye (2) into Position (X) on the CEM bracket (4). Install bolts (3) tighten the bolts to a torque of 78 N m (58 lb ft).
Reconnect the inlet manifold temp and pressure sensor. Refer to Disassembly and Assembly, Inlet Manifold Temperature and Pressure Sensor - Remove and Install for the correct procedure.
Reconnect the EGR temperature sensor to Disassembly and Assembly, Temperature Sensor (Cooled Exhaust Gas) - Remove and Install for the correct procedure.
Reconnect the coolant temperature sensor. Refer to Disassembly and Assembly, Coolant Temperature Sensor - Remove and Install for the correct procedure.
Position the harness assembly onto the cylinder head. Use new cable straps to secure the harness assembly to the cylinder head. Ensure that cable straps meet the OEM specification. Ensure that the harness assembly is not strained.Note: Ensure that the harness assembly is positioned correctly and clear of other engine components.