3802116 Volvo.Penta Turbocharger

Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove bolts (1) and rocker shaft assembly (2). Remove the O-ring seal from the rear rocker arm support bracket.2. Put identification marks on push rods (3) as to their location in the engine. Remove the push rods. The following steps are for the installation of the rocker shaft assembly and push rods.3. Loosen the adjusting screws (4). This will prevent a bent valve or push rod during installation of the rocker shaft assembly. Install push rods (3). The O-ring seal in the rear support must be installed new each time the bolt is removed from the rear support bracket.4. Install rocker shaft assembly (2).
Make sure the dowels on each end of the rocker shaft assembly are in alignment with the holes in the cylinder head.
5. Put 2P2506 Thread Lubricant on all of bolts (1) except for bolt (10) that goes through the rear rocker arm support bracket. Install the bolts in the rocker shaft assembly.6. Tighten bolts (1) for the rocker shaft as follows: a. Tighten all the bolts in number sequence to a torque of 155 N m (115 lb ft).b. Tighten all the bolts again in number sequence to a torque of 250 17 N m (185 13 lb ft).c. Last, tighten bolts again in number sequence (hand tighten only to a torque of 250 17 N m (185 13 lb ft).7. The assembled length of springs at both ends of rocker shaft must be 1.50 0.25 mm (.059 .010 in). Remove or install washers behind springs to change the assembled length of the springs.8. Make adjustments until the intake valve clearance is .038 mm (.015 in) and the exhaust valve clearance is 0.64 mm (.025 in). See the topic, Valve Clearance Setting, in Testing And Adjusting. Tighten the locknuts (2) for the adjusting screws (1) to a torque of 29 7 N m (21 5 lb ft).End By:a. install valve cover.Disassemble And Assemble Rocker Shaft
Start By:a. remove rocker shaft and push rods
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove O-ring seal (1). A replacement of the O-ring seal must be made each time the head bolt is removed from the rear support bracket. 2. Remove retainer ring (6), washer (5), spring (4) washer (3) and rocker arm (2). 3. Remove pin from rear support bracket with a hammer and punch. Remove rear support bracket (7).4. Remove remainder of rocker arms, springs, washers and brackets.5. Remove plugs from each end of the shaft if necessary. The following steps are for the assembly of the rocker shaft. 6. Install rocker arms (2), brackets (8), washers (5) and springs (4) on the rocker shaft.7. Install rear support bracket (7). Make sure the hole in rear support bracket is in alignment with the hole in rocker shaft.8. Install pin (9) through bracket and shaft with a hammer.9. Pin (9) must extend 9.60 mm (.378 in) above the bracket.10. Install O-ring seal (1). Install rocker arm (2), washer, spring, washer and retainer ring.11. Install the plugs in each end of the rocker shaft if they were removed.End By:a. install rocker shaft and push rods