3801202 Volvo.Penta Upper gear, exch

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Guide Stud
(M11 x 1.25 by 100 mm) 2
B 8T-3052 Degree Wheel 1
Thoroughly clean the gasket surfaces of the cylinder head and the cylinder block. Do not damage the gasket surfaces of the cylinder head or the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.
Inspect the gasket surface of the cylinder head for distortion. Refer to Specifications, "Cylinder Head" for more information. If the gasket surface of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head.
Illustration 1 g06116068
Typical example
Illustration 2 g06116059
Inspect dowels (7) for damage. If necessary, replace the dowels in the cylinder block.
Install Tooling (A) to the cylinder block. Refer to Illustration 2.
Ensure that new cylinder head gasket (6) is the same thickness as the cylinder head gasket that was previously removed. The thickness of the cylinder head gasket is indicated by the number that is shown at Position (X). Refer to Specifications, "Cylinder Head" for more information.
Align cylinder head gasket (6) with Tooling (A) and with dowels (7). Install the cylinder head gasket onto the cylinder block.
Illustration 3 g03865408
Use a suitable lifting device to lift cylinder head (5). The weight of the cylinder head is approximately 30 kg (66 lb).
Use Tooling (A) to align the cylinder head with the cylinder block. Install the cylinder head to the cylinder block.Note: Ensure that the cylinder head is correctly positioned onto the dowels.
Remove Tooling (A).
Install new bolts (4) to the cylinder head.
Illustration 4 g06116077
Cylinder head tightening sequence for three cylinder engines
Tighten bolts (4) to a torque of 50 N m (36 lb ft). Use the numerical sequence that is shown in Illustration 4
Use Tooling (B) to turn the bolts through an additional 150 degrees in the numerical sequence as shown in 4.
Illustration 5 g03865410
Position clamp (2) onto hose (1). Connect the hose to outlet (3). Tighten the hose clamp securely.End By:
Install the water temperature regulator to the cylinder head. Refer to Disassembly and Assembly, "Water Temperature Regulator - Remove and Install" for the correct procedure.
Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install" for the correct procedure.
Install the glow plugs. Refer to Disassembly and Assembly, "Glow Plugs - Remove and Install" for the correct procedure.
Install the fuel manifold. Refer to Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install" for the correct procedure.
Install the fuel injectors. Refer to Disassembly and Assembly, "Fuel Injector - Install" for the correct procedure.
Install the inlet manifold. Refer to Disassembly and Assembly, "Inlet Manifold - Remove and Install" for the correct procedure.
Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install" for the correct procedure.
Install the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base (Secondary Fuel Filter) - Remove and Install" for the correct procedure.
Install the crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather - Remove and Install" for the correct procedure.