860902 Volvo.Penta Pipe elbow

a) Remove fuel lines (1).b) Remove water line (3) to the aftercooler.c) Remove bracket (2) that holds the turbocharger supply line to the engine. 2. Disconnect breather tubes (5). Remove valve covers (4). 3. Disconnect fuel lines (7) with tool (A). Disconnect the clips from the fuel lines and wires (8) from the glow plugs. Disconnect wires (6) from the valve cover housing. 4. Remove the bolts that hold the valve cover housing to the cylinder head. Remove valve cover housing (9). 5. Loosen bolts (12) evenly and remove rocker shaft assembly (10). Remove push rods (11). 6. Remove water lines (13) to the air compressor. Disconnect wire (14) to water temperature sending unit.7. Remove the bolts that hold the lift bracket to the cylinder head. Remove lift bracket (15). 8. Remove the bolt from the automatic advance housing to the bracket. Remove two brackets (16) from the cylinder head. Remove the remainder of the 3/8"-16 NC bolts (17) from the cylinder head. 9. Disconnect step bracket (18) from the cylinder head. See SPECIAL INSTRUCTION Form No. SMHS7072 to make the repairs to loose bridge dowels. 10. Remove glow plug wiring harness (19). Put identification on the valve bridges for installation purposes. Remove valve bridges (20). 11. Loosen fourteen cylinder head bolts (21) and remove all bolts except the center bolt. 12. Install three 5/16"-18 NC forged eyebolts to the cylinder head. Fasten a hoist to upper part of the cylinder head. Fasten tool (B) to the hoist and to the lower part of cylinder head. Remove bolt (21). Remove cylinder head (22). Weight of cylinder head is 250 lb. (113 kg).
LATER MANIFOLD13. Remove locknuts and washers (23). Remove exhaust manifolds as a unit. A new plate gasket must be installed when the cylinder head is removed. See REMOVE AND INSTALL SPACER PLATE.Install Cylinder Heads
LATER MANIFOLD1. Make sure all parts are clean. Check all gaskets and seals for damage. If damaged, use new parts for replacement. Put 5P3931 Anti-Seize Compound on the threads of studs (3).2. Put gaskets (1) in position on the cylinder heads.3. Install exhaust manifolds as a unit. Install spacers, washers and locknuts (2) to hold the exhaust manifolds in position. Tighten the nuts to a torque of 38 5 lb.ft. (52 7 N m). A new spacer plate gasket must be installed when the cylinder head is removed. See REMOVE AND INSTALL SPACER PLATE. 4. Thoroughly clean the spacer plate and bottom surface of the cylinder heads. Install a new head gasket (5) and seals (4). Do not use any adhesives. 5. Install three 5/16"-18 NC forged eyebolts in cylinder head. Fasten a hoist and tool (A) to the cylinder head. Put cylinder head (6) in position on the cylinder block.6. 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 20 N m).c) Tighten bolts 1 through 14 in number sequence to a torque of 330 15 lb.ft. (447 20 N m). 7. Install valve bridges (7) in their respective positions. Install glow plug wiring harness (8). 8. Connect step bracket (9) to the cylinder head. 9. Put bracket (10) and bracket (11) in position on cylinder head. Tighten the bolt that holds the automatic timing advance to bracket (10) to standard torque. Install 3/8"-16 NC head bolts (12). Install the remainder 3/8" bolts that hold the brackets to the cylinder head. Tighten the 3/8" head bolt to a torque of 32 5 lb.ft. (43 7 N m). 10. Connect wire (15) to the water temperature sending unit. Install water lines (13) from the air compressor.11. Install the lifting bracket (14). 12. Install the push rods. Put rocker shaft assembly (16) in position. Make an alignment of the push rods and rocker arms. Put clean engine oil on the thread of bolts (17) through (20). Install bolts and washers. Tighten the bolts as follows: a) Tighten bolts (17) through (20) in number sequence to a torque of 200 20 lb.ft. (270 25 N m).b) Tighten bolts (17) through (20) in number sequence to a torque of 330 15 lb.ft. (447 20 N m).c) Tighten bolts (17) through (20) in number sequence again to a torque of 330 15 lb.ft. (447 20 N m).13. Check bridge adjustment. See BRIDGE ADJUSTMENT in TESTING AND ADJUSTING.14. 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. 15. Put valve cover base (21) in position on the cylinder head. 16. Tighten the bolts that hold the valve cover base on the cylinder head in the number sequence shown to a