424667 Volvo.Penta Suction pipe

Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2
B 339-9352 Injector. Cap Kit 1
265-2256 Wipers 1
C 5P-1755 Shim 1
D 312-2840 Socket 1 Start By:
Remove exhaust manifold.
Remove rocker shaft and pushrods.
Remove 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, the exterior of the components needs to be thoroughly cleaned. The cleaning helps to prevent 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 always.
Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for correct draining and filling procedure.
Illustration 1 g02088484
Do not open the high pressure fuel system without allowing the fuel system to purge. After the engine has shut down, allow the fuel system to purge for ten minutes. This operating fuel system contains high pressure. Exposure to high pressure fuel can result in personal injury.
Remove bolts (1). Disconnect exhaust manifold (2). Remove bolts (11). Disconnect inlet manifold (12).
Remove bolt (8) and the washer. Remove tube assembly (5). Disconnect harness assembly (9).
Remove bolts (10) and bolts (7). Remove tube assembly (6).Note: Exercise care in removing the cylinder head and the gasket 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) starting with the outboard side and work toward inboard side. Remove the top bolt last. Install Tooling (C) between the cylinder head and the cylinder block surface to cover the oil supply hole.
Remove cylinder head (3) from the engine. Position cylinder head (3) onto suitable cribbing to prevent damage.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 g02149623
Remove Tooling (C). Remove dowel assembly (14) and install Tooling (B) .
Remove gasket (13) from the cylinder block. Remove fire ring (15).Installation Procedure
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 always.
Illustration 3 g02149623
Remove the O-ring seals from dowel assembly (14), clean, and inspect. If necessary, replace the O-ring seals with new. Remove Tooling (B) and clean oil supply hole. Install dowel assembly (14).
Inspect fire ring (15) for damage and install new, if necessary. Install fire ring (15). Install a new gasket (13) onto the cylinder block.
Illustration 4 g02090574
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 g02161103
Hand tighten all bolts (4) in the numerical sequence to a maximum torque of 15 N m (133 lb in). Use Tooling (D) to tighten bolts (4) in the numerical sequence to a torque of 100 10 N m (75 7 lb ft). Tighten bolts (4) again in the numerical sequence to a torq