21228793 Volvo.Penta Pump unit

CAUTIONDo not put a force on the fuel injection rack or cause damage to it when the injectors are removed.
8. Use a pry bar to loosen fuel injector (9) and remove the injector from the cylinder head. 9. Remove a section of water manifold (12) and elbows (13) from the cylinder head.10. Remove the bolts that hold air inlet elbow (15) and exhaust manifold (14) to the cylinder head.11. Fasten a hoist to cylinder head (16) with tooling (B). Remove bolts (17) and (18) to remove cylinder head (16) from the engine. The weight of the head is 45 kg (100 lb.).12. Remove head gasket (19) and the seals from the spacer plate. Remove spacer plate (20) and the gasket from the cylinder block. INSTALL CYLINDER HEADS
A new spacer plate gasket must be installed when the cylinder head is removed. See REMOVE AND INSTALL SPACER PLATE.1. Thoroughly clean the spacer plate and bottom surface of the cylinder head. Install a new spacer plate gasket and the spacer plate on the cylinder block. Install a new head gasket and seals on the spacer plate. Do not use any adhesives.2. Put the gaskets for the exhaust manifold and air inlet elbow in position.3. Fasten a hoist to the cylinder head with tooling (A). Put the cylinder head into position on the spacer plate.4. Put clean engine oil 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 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 25 lb.ft.).c) Tighten bolts 1 through 8 in number sequence to a torque of 450 20 N m (330 15 lb.ft.).5. Install bolts (1) and the washers. Tighten the bolts to a torque of 55 10 N m (40 7 lb ft).6. Put 5P3931 Anti-Seize Compound on the threads of the bolts for exhaust and manifold (2) and install the bolts and washers to hold manifold (2) to the cylinder head.7. Install the bolts and washers to hold air inlet elbow (3) to the cylinder head.8. Put the gaskets, water manifold (4) and elbows (5) in position as a unit and install the bolts. 9. Make sure the three O-ring seals are installed on injector (6) and put clean engine oil on them and in the bore for the injector.
CAUTIONDo not tap or hit on the injector follower to install the injector. Damage and failure to the injector can be the result.
10. Put injector (6) in position. Install the clamp, washer and bolt. Tighten the bolt to push injector (6) all the way in its bore. Tighten the bolt to a torque of 65 7 N m (48 5 lb.ft.).11. Check to make sure the fuel injection rack moves freely by hand in the injector after the injector is installed.12. Make sure the O-ring seals are installed around the three dowels in the bottom of valve cover base (7). Put the gasket and base (7) in position and install the bolts to hold them to the cylinder head.13. Put fuel control rod assembly (9) and lever assembly (8) in position in the cylinder head. If necessary, use tool (B) to turn the engine flywheel until the camshaft moves enough to permit the lever of rod assembly (9) to move into position.14. 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.15. See TESTING AND ADJUSTING section for the correct adjustment of the fuel injection control group.16. Make sure the lever for the fuel control and assembly is in position on control shaft (10) and install the bolt and cap (11).17. Install the access cover and seal over the camshaft and control shaft (10).18. Make sure the O-ring seals for the fuel manifold and lines are installed and have clean engine oil on the seals. Install fuel manifold (12) and fuel lines (13) on the engine.19. Turn the fuel supply to the engine.20. Fill the cooling system with coolant to the correct level.end by:a) install rocker shafts and push rods