238744 Volvo.Penta Spring

start by:a) remove rocker shaft and push rodsb) remove fuel injection linesc) remove refrigerant compressor **This operation is in Air Conditioning and Heating Service Manual Form No. SENR7454.1. Drain the coolant from the cooling system. 2. Remove two bolts (2) from the top of the water pump housing.3. Remove two bolts (3) that hold the bracket for the transmission oil filter to the cylinder head.4. Remove water temperature sensing line (4) from the cylinder head.5. Loosen two clamps (1). Slide the hose up on the elbow that is fastened to the radiator.6. Loosen the tension in the vee belts for the fan and alternator.7. Fasten a hoist to the fan and fan drive. Remove the four bolts that hold the fan drive to the cylinder head. Move the fan and fan drive toward the radiator core. 8. Install tool (A) in the front of the cylinder block as shown. Fasten the fan drive to tool (A). Tool (A) will hold the fan and fan drive up when the cylinder head is removed. 9. Remove clip (8) that holds the wire harness for the glow plugs in position on cylinder head.10. Remove bracket (5) for the hydraulic oil tube assemblies.11. Remove inlet tube assembly (6) for the turbocharger. Remove return tube assembly (9) from the turbocharger.12. Remove bracket (7) for the refrigerant compressor. 13. Install tool (B) in the cylinder head as shown.14. Remove bolts (10) that hold the cylinder head to the cylinder block. 15. Fasten a hoist to tool (B). Fasten tool (C) to the exhaust manifold and the hoist. Remove cylinder head assembly (11). The weight of the cylinder head assembly is 205 kg (455 lb.).Install Cylinder Head Assembly
1. Clean the machined surfaces of the cylinder head and cylinder block that make contact with the cylinder head gasket. 2. Put a new cylinder head gasket in position on the cylinder block. Make sure the holes in the cylinder head gasket are all in alignment with the holes in the cylinder block. Fasten a hoist to cylinder head assembly (1) and put it in position on the cylinder block. 3. Install the push rods. Put the rocker shaft in position on the cylinder head.
Make sure the dowels in the rocker shaft assembly are in alignment with the holes in the cylinder head before the bolts are installed and tightened.
4. Put 5P3931 Anti-Seize Compound on the threads of the cylinder head bolts and rocker shaft bolts. Install the bolts and washers and tighten the bolts as follows: a) Tighten all the bolts in number sequence to a torque of 155 N m (115 lb. ft.).b) Tighten all bolts in number sequence to a torque of 250 17 N m (185 13 lb. ft.).c) Tighten all bolts in number sequence (hand turn only) to a torque of 250 17 N m (185 13 lb. ft.).d) Tighten all bolts in letter sequence to a torque of 28 N m (22 lb. ft.).e) Tighten all bolts in letter sequence to a torque of 43 7 N m (32 5 lb. ft.).f) Tighten all bolts in letter sequence (hand turn only) to a torque of 43 7 N m (32 5 lb. ft.). 5. Make adjustments until the intake valve clearance is 0.38 mm (.015 in.) and the exhaust valve clearance is 0.64 mm (.025 in.). See VALVE CLEARANCE SETTING in TESTING AND ADJUSTING.6. Install the valve cover. See Install Valve Cover.7. Fasten a hoist to the fan drive and remove it from tool (A). Remove tool (A) from the front of the cylinder block and fasten the fan drive to the cylinder head. Make an adjustment to the vee belt tension. See V-Belt tension chart in the Specifications. 8. Install bracket (3) for the refrigerant compressor.9. Install inlet tube assembly (6) and return tube assembly (4) for the turbocharger.10. Put the wire harness for the glow plugs in position and install clip (5). Connect the wires to the glow plugs.11. Install bracket (2).12. Install the two bolts that hold the housing for the water pump to the cylinder head.13. Install the two bolts that hold the bracket for the transmission oil filter to the cylinder head.14. Install the water temperature sensing line in the cylinder head.15. Slide the hose for the inlet elbow for the radiator in position. Tighten the two clamps that hold it.16. Fill the cooling system with coolant to the correct level. See Lubrication and Maintenance Guide.end by:a) install refrigerant compressor *b) install fuel injection linesc) install air cleaner assembly*This operation is in the Air Conditioning and Heating Service Manual Form No. SENR 7454.