837080 Volvo.Penta Repair kit

Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2
B 339-9352 Inj. Sys Cap Kit 1
265-2256 Wipers 1
D 312-2840 Socket 1 Start By:
Remove the rocker shaft and pushrods.
Remove the electronic unit injector.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Use Tooling (B) to prevent contamination. Cleanliness is an important factor. Before you begin the disassembly procedure, thoroughly clean the exterior of the components. To prevents dirt from entering the internal mechanism. Precision components can be damaged by contaminants or by dirt. Perform disassembly procedures on a clean work surface. Keep components covered and protected at all times.
Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
Illustration 1 g02419599
Remove bolts (2). Remove heat shield (1). Remove the bolts and disconnect the exhaust manifold. Remove bolts (5). Disconnect inlet manifold (6).Note: Exercise care in removing the cylinder head and the gasket in order to avoid contamination of oil supply holes in the cylinder block.
Attach Tooling (A) and a suitable lifting device onto cylinder head (3). Cylinder head (3) weighs approximately 68 kg (150 lb). Remove bolts (4). Remove cylinder head (3) from the engine.Note: The positioning dowels need to remain in the cylinder block. Remove the dowels if the dowels remain in the cylinder head. Install the new dowels in the cylinder block before installing the cylinder head.
Illustration 2 g02419617
Remove Integral seal (7) from the cylinder block. Remove fire ring (8).Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2
B 339-9352 Inj. Sys Cap Kit 1
265-2256 Wipers 1
C 1P-0808 Multipurpose Grease 1
D 312-2840 Socket 1 Note: When Tooling (B) is removed be careful to prevent contamination. Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Dirt and other contaminants can damage the precision component. Perform assembly procedures on a clean work surface. Keep components covered and protected at all times.
Illustration 3 g02419617
Inspect fire ring (8) for damage and install new, if necessary. Install fire ring (8). Install a new Integral seal (7) onto the cylinder block.
Illustration 4 g02419897
Attach Tooling (A) and a suitable lifting device onto cylinder head (3). Cylinder head (3) weighs approximately 68 kg (150 lb). Position cylinder head (3) onto the cylinder block. Lubricate the threads of bolts (4) with oil. Install bolts (4).
Illustration 5 g02090575
Hand tighten bolts (4) in the numerical sequence to a maximum torque of 15 N m (11 lb ft). Use Tooling (D) to tighten bolts (4) in the numerical sequence to a torque of 100 10 N m (75 7