860777 Volvo.Penta Repair kit

2. Remove bolt (1) that holds the wiring harness to the cylinder head. 3. Remove bolts (3) and (4). Pull breather tube (2) away from the cylinder head. 4. Remove elbow (5) and the gasket from the cylinder head. 5. Loosen clamps (6) and push the hose from elbow (7). Remove elbow (7) and the water temperature regulator from the cylinder head.6. Remove tube assemblies (9) and (10) from the engine.7. Disconnect temperature sending unit (8) from the cylinder head. 8. Remove bolts (11) to disconnect the water pump elbow from the cylinder head. 9. Loosen the bolts that hold the alternator in position to remove the tension on vee belts (12). Remove the vee belts from the alternator pulley.10. Fasten a hoist to the fan and fan drive as shown. Remove bolts (13) and lower the fan and fan drive to the timing gear cover. The weight of the fan and fan drive is 55 lb. (25 kg). 11. Fasten a hoist to the cylinder head. Remove the bolts that hold the cylinder head to the cylinder block. Remove the cylinder head and gasket. The weight of the cylinder head is 150 lb. (68 kg).Install Cylinder Head
1. Clean the surfaces of the cylinder head and the cylinder block that make contact with each other. Make sure the surfaces are clean and dry. Install a new, dry gasket (2) on the cylinder block.2. Make sure the gasket for elbow (1) is in position.3. Fasten a hoist to the cylinder head and put it in position on the cylinder block.4. Put 5P3931 Anti-Seize Compound on all the head bolts and rocker shaft bolts. Install the head bolts and washers that hold the head in place. Do not tighten bolts at this time. 5. Install the push rods and rocker shaft assembly (3). Install the bolts and washers that hold the rocker shaft assembly in place.6. Tighten the bolts as follows: a) Tighten bolts 1 through 18 in number sequence to a torque of 115 lb.ft. (155 N m).b) Tighten bolts 1 through 18 again in number sequence to a torque of 185 13 lb.ft. (250 17 N m).c) Tighten bolts 1 through 18 again in number sequence (hand tighten only) to a torque of 185 13 lb.ft. (250 17 N m).d) Tighten bolts A through E in letter sequence to a torque of 22 lb.ft. (28 N m).e) Tighten bolts A through E again in letter sequence to a torque of 32 5 lb.ft. (43 7 N m).f) Tighten bolts A through E again in letter sequence (hand tighten only) to a torque of 32 5 lb.ft. (43 7 N m).7. Make adjustments until the intake valve clearance is .015 in. (0.38 mm) and the exhaust valve clearance is .025 in. (0.64 mm). See ENGINE VALVE LASH as shown in MAINTENANCE GUIDE. Tighten the locknuts for the adjustment screws to a torque of 21 5 lb.ft. (26 7 N m).8. Put the valve cover in position and install the bolts. See INSTALL VALVE COVER for correct torque and tightening sequence. 9. Install pipe assembly (4) and the gasket on the cylinder head. 10. Install bolts (6) to hold the elbow to the cylinder head.11. Connect water temperature sending unit (7) to the cylinder head.12. Use a hoist to put fan and fan drive (5) in position. Install the bolts that hold the fan drive bracket to the cylinder head.13. Put the vee belts in position on the alternator pulley.14. Make an adjustment of the vee belts. See, Install Alternator. 15. Install tube assemblies (10) and (11).16. Install water temperature regulator (9) in the cylinder head with the spring toward the inside.
If the water temperature regulator is installed wrong, it will cause the engine to overheat.
17. Put the gasket and elbow (8) in position and install the bolts to hold it. Connect the hose from the radiator top tank to elbow (8) and tighten the clamps. 18. Install the bolt and washer to hold wiring harness (12) to the cylinder head. Install the glow plug wire lead assembly and connect it to wiring harness (12). 19. Put breather tube (14) in position. Install the two bolts (15) and the bolts that hold tube (14) to the timing gear cover and fuel injection pump housing. Tighten the clamps on hose (13).20. Fill the cooling system with coolant to the correct level.end by:a) install exhaust manifoldb) install air cleaner housingc) install fuel injection lines