838928 Volvo.Penta Plug

1. Remove four bolts (1) from the turbocharger tube adapter to the aftercooler housing. Loosen the turbocharger compressor housing clamp, and rotate turbocharger tube (2) out of the way of the cylinder head assembly. 2. Remove bolts (3) that hold the valve cover bases to the cylinder head assembly. Remove valve cover bases (4).
To prevent damage to the fuel injection nozzle, hold adapter assembly (5) in position at the of injection nozzle (6) when fuel line nut (7) is loosened or tightened.
3. Use tool (A) and a 7/8 5P328 Crow Foot ( in) to loosen the fuel injection line nut at the nozzle end. 4. Use tool (B) to loosen the nut at the fuel injection line adapter end. Remove inner fuel injection lines (8). Install caps and plugs on all fuel injection line openings to keep dirt out of the fuel system. 5. Remove bolts (9) that hold the rocker shaft assemblies to the cylinder head assembly.6. Remove rocker shaft assemblies (10). 7. Put identification marks on the push rods as to their location in the engine. Remove push rods (11). 8. Put identification marks on the bridges as to their location in the engine. Remove bridges (12) from the dowels on the cylinder head assembly.Install Rocker Shaft Assemblies & Push Rods
1. Put clean engine oil on the bridges and dowels. Install the original bridges in their respective locations. New bridges can be mixed.2. Install bridges (1) on the bridge dowels. While firmly pressing 0.5 to 4.5 Kg (1 to 10 lb) straight down on the top contact surface of the bridge, turn the adjusting screw clockwise until contact is made with the valve stem. Turn the screw an additional 1/31/2 20° to 30° ( to of 1 hex on nut). This will straighten the dowel in the guide and compensate for the slack in the threads. Hold the adjusting screw in this position and tighten the locknut to a torque of 30 4 N m (22 3 lb ft). Install the original push rods in their respective locations in the engine. New push rods can be mixed.3. Install push rods (2). 4. Put rocker shaft assemblies (3) in position on the cylinder head assembly.5. Put clean engine oil on the threads of the bolts that hold the rocker shaft assemblies in place. Tighten the bolts first to a torque of 270 25 N m (200 18 lb ft). Start with the bolt in the center of the rocker shaft assembly. Tighten the bolts again to a torque of 450 20 N m (330 15 lb ft). Tighten the bolts again by hand to a torque of 450 20 N m (330 15 lb ft).
Do not cause damage to the O-ring seals on the inner fuel lines.
6. Install inner fuel injection lines (4). Tighten the fuel injection line adapter nuts (5) to a torque 40 7 N m (30 5 lb ft) with tool (A).
Do not let the tops of the fuel nozzles turn when the fuel lines are tightened. The nozzles will be damaged if the top of the nozzles turns in the body.
7. Tighten fuel injection line nut (6) to a torque of 40 7 N m (30 5 lb ft) with tool (B) and a 7/8 5P328 in Crow Foot wrench.8. Make adjustments to the valves until the intake valve clearance is 0.38 mm (.015 in) and the exhaust valve clearance 0.76 mm (.030 in). See Valve Clearance Setting in Testing And Adjusting. Tighten the locknut to a torque of 30 4 N m (22 3 lb ft) and check the adjustments. 9. Install valve cover bases (7) on the cylinder head assembly. Install bolts that hold the valve cover bases in place. Tighten the bolts to a torque of 14 N m (10 2 lb ft). 10. Rotate turbocharger tube (8) into position. Place a gasket between the aftercooler housing and adapter. Install four bolts and nuts that hold the tube to the aftercooler housing.11. Tighten turbocharger clamp nut (9) to a torque of 18 3 N m (13 2 lb ft). Lightly hit all around the clamp nut with a soft faced hammer again to the same torque value.End By:a. install valve covers