3842637 Volvo.Penta Reversing gear kit

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     1U-5686 (1)     21/32 inch Drill Bit     1    
B     4C-9732 (1)     M16x2.0-D7 Plug Tap     1    
C     9U-5604     M16x2.0 32mm Heli-Coil Insert (2)     1    
D     8T-2799 (1)     Heli-Coil Installation Tool     1    
E     8T-3096     Plug Tap     1    
F     6V-4876     Lubricant     1    
( 1 ) Part of 4C-8367 Thread Repair Kit
( 2 ) This is a special length.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Thoroughly clean the mating surfaces of the cylinder head and the cylinder block.
Clean all 26 head bolt holes on the cylinder block with Tooling (E) .
After cleaning the threads, remove any debris from the head bolt holes on the cylinder block with a vacuum hose.
Visually inspect the head bolt holes on the cylinder block for thread damage.
If a damaged head bolt thread is observed, repair the damaged head bolt thread with a Heli-Coil thread repair kit.
Inspect the cylinder head and the cylinder block for flatness. Refer to Guideline for Reusable Parts and Salvage Operations, SEBF8162, "Procedure to Measure and Salvage Cylinder Head Assemblies and Related Components".
Install the new O-ring seals and the new cylinder head gasket on the cylinder block.
Illustration 1 g01109669
Illustration 2 g01109676
Attach a suitable lifting device to cylinder head (3). The weight of the cylinder head is approximately 295 kg (650 lb). Position cylinder head (3) on the cylinder block.
Install new bolts (2) .
Lubricate the following components with Tooling (F) : the bolt threads, the underside of the bolt heads and the washers. Follow Step 11 for the correct tightening procedure.
Illustration 3 g00517501
Tighten the cylinder head bolts according to the following procedure:
Tighten bolt (1) through bolt (26) in a numerical sequence to a torque of 160 15 N m (120 11 lb ft).
Tighten bolt (1) through bolt (26) again in a numerical sequence to a torque of 160 15 N m (120 11 lb ft).
Place an index mark on each bolt head. Turn bolt (1) through bolt (26) in a numerical sequence for an additional 90 degrees (1/4 turn).
Loosen bolt (1) through bolt (26) until the washers are loose under the bolt heads.
Tighten bolt (1) through bolt (26) in a numerical sequence to a torque of 160 15 N m (120 11 lb ft).
Tighten bolt (1) through bolt (26) again in a numerical sequence to a torque of 160 15 N m (120 11 lb ft).
Place an index mark on each bolt head. Turn bolt (1) through bolt (26) in a numerical sequence for an additional 90 degrees (1/4 turn).
Tighten bolt (27) through bolt (33) in a numerical sequence to a torque of 28 7 N m (20 5 lb ft).
Connect oil drain tube assembly (12) (not shown) to the turbocharger.
Connect tube assembly (15) .
Connect hose (11), hose (13), and hose (14) .
Connect harness assembly (10) .
Install bracket (6) .
Position hour meter (9) and fuel filter base (7) on the engine.
Reposition breather assembly (8) on the engine.
Reposition harness assembly (5) on the engine.
Install tube assembly (1) and tube assembly (4) .End By:
Install the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Install".
Install the water outlet manifold. Refer to Disassembly and Assembly, "Water Outlet Manifold - Install".
Install the valve mechanism cover base. Refer to Disassembly and Assembly, "Valve Mechanism Cover Base - Remove and Install".