20523556 Volvo.Penta Shim

At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to release the relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
1. Drain the coolant from the cooling system into a suitable container for storage or disposal.2. Shut off the fuel supply to the engine. 3. Remove fuel lines (2) from the cylinder head and fuel line manifold (1). Remove the bolts and remove fuel line manifold (1) and the bracket from the cylinder head. 4. Remove the access cover from over the camshaft and remove bolt (4) and cap (5) that hold fuel rod assembly (3) to the fuel control shaft.5. Remove bolts (7) and remove lever assembly (6) and fuel rod assembly (3) as a unit. If necessary, remove the cover from the front right side of the flywheel housing and use Tool (A) to turn the engine flywheel until the camshaft is moved in a position so the lever of rod assembly (3) can be removed between the engine block and camshaft. 6. Remove the bolts and remove valve cover base (10) and the gasket from the cylinder head.7. Remove bolt (8) and clamp (11) from the fuel injector.
Do 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 strap and a suitable lifting device to cylinder head (16) with Tool (B). Remove bolts (17) and (18) to remove cylinder head (16) from the engine. The weight of the cylinder 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 the topic Remove & 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 space plate. Do not use any adhesives.2. Put the gaskets for the exhaust manifold and air inlet elbow in position. 3. Fasten a strap and a suitable lifting device to the cylinder head with Tool (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 cylinder head 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 washers to hold the cylinder head to the engine. Tighten bolts (1) 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 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.
Do not tap or hit on the injector follower to install the injector. Damage or 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 the Testing & Adjusting Manual 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 on the fuel supply to the engine.20. Fill the cooling system with coolant to the correct level. See the Operation & Maintenance Manual.End By:a. install rocker shafts and push rods