832887 Volvo.Penta Piston

Start By:a. remove exhaust manifolds The exhaust manifolds do not have to be removed unless all of the cylinder head assemblies are to be removed.1. Drain the coolant from the cooling system.2. Shut off the fuel supply to the engine. 3. Remove the bolts, and remove intake elbow (1) from the cylinder head assembly. 4. Disconnect fuel lines (2) and (4) from fuel manifold (3). Remove bolts (5), and remove fuel manifold (3).5. Remove the rocker shaft assemblies and push rods. See Remove Rocker Shaft Assemblies And Push Rods for this procedure. 6. Remove the bolts and cover (6) from under the cylinder head assembly to be removed. 7. Remove bolt (8) and cap (7) that hold the fuel control lever to the fuel control shaft. 8. Remove bolts (13) to remove lever assembly (9) and rod assembly (14) as a unit from the cylinder head assembly.9. If necessary, use tool (A) to turn the flywheel until the camshaft is moved in a position so rod assembly (14) can be removed between the engine block and camshaft.10. Remove bolt (10) and clamp (12) from fuel injector (11).
Do not put a force on the fuel injection rack or cause damage to it when the injectors are removed.
11. Use a pry bar to remove injector (11) from the cylinder head assembly. 12. Remove fuel lines (17), bracket (16) and elbows (15) from the cylinder head assembly.13. Remove bolts (18) and (20) to remove valve cover base (19) from the cylinder head assembly. 14. Use tooling (B) to fasten a hoist to cylinder head assembly (22). Remove bolts (21) and (23) to remove cylinder head assembly (22) from the engine. The weight of the cylinder head assembly is 45 kg (100 lb.).Install Cylinder Head Assemblies
1. Thoroughly clean the spacer plates and bottom surface of the cylinder head assemblies. Install a new spacer plate gasket, head gasket and seals. Do not use any adhesives. Before installation of the cylinder head assembly on a water cooled manifold, be sure there is not a plug at location (X). 2. Fasten a hoist and tooling (A) to the cylinder head assembly with two 3/8"-16 NC bolts and washers as shown. Put the cylinder head assembly into position on the spacer plate. 3. Put 5P3931 Anti-Seize Compound on the threads of the cylinder head bolts. Install the cylinder head bolts and washers. Tighten the bolts in the following sequence:a. Tighten all of the bolts to a torque of 30 5 N m (22 4 lb ft).b. Tighten bolts 1 through 8 in number sequence to a torque of 270 35 N m (200 26 lb ft).c. Tighten bolts 1 through 8 in number sequence to a torque of 450 20 N m (332 15 lb ft). 4. Install bolts (3) and the washers to hold the cylinder head assembly to the engine.5. Make sure the O-ring seals are installed around the two dowels in the bottom of valve cover base (2). Put the gasket and base (2) in position, and install the bolts to hold them to the cylinder head assembly.6. Install elbows (1) with a gasket on the cylinder head assembly. 7. Install bracket (5) and fuel lines (6) on the cylinder head assembly.8. Make sure the three O-ring seals are installed on injector (4), and put clean engine oil on them and in the bore for the injector.
Do not tap or hit on the injector follower to install the injector. Damage and failure of the injector can be the result.
To prevent a carbon deposit between the injector and the injector bore, make sure the injector body (especially the tapered area) and the injector bore are clean and free of foreign material.9. Put injector (4) in position. Install the clamp, washer and bolt. Tighten the bolt to push injector (4) all the way in its bore. Tighten the bolt to a torque of 65 7 N m (48 5 lb ft).10. Check to make sure the fuel injection rack moves freely by hand in the injector after the injector is installed.11. Install fuel control rod assembly (7) in the cylinder head assembly and cylinder block. If necessary, use tool (B) to turn the engine flywheel until the camshaft moves enough to permit the lever of rod assembly (7) to move into position. 12. Connect lever assembly (8) to the control rod assembly. Make sure lever assembly (8) is engaged correctly with the fuel injection rack, and install the two bolts and washers to hold it in place.13. See Testing and Adjusting section for the correct adjustment of the fuel injection control group. 14. Make sure the lever for the fuel control rod assembly is in position on control shaft (9), and install the bolt and cap (10). 15. Install cover (12) and seal (11) over the camshaft and control shaft (9).16. Install the rocker shaft assemblies and push rods. See Install Rocker Shaft Assemblies And Push Rods for this procedure. 17. Put clean engine oil on the O-ring seals, and install fuel manifold (14). Connect fuel lines (6) and (13) to fuel manifold (14). 18. Put the gaskets and intake elbow (15) in position, and install the bolts to hold intake elbow (15) in place.19. Turn on the fuel supply to the engine.20. Fill the cooling system with coolant to the correct level. See the Maintenance Manual for the correct fluid level.End By:a. install exhaust manifolds