21259401 Volvo.Penta Water inlet

Table 1
Required Tools
Tool Part Number Part Description Qty
A 371-1079 Lifting Plate 1
B 339-9352 Inj. Sys. Cap Kit 1
265-2256 Wipers 1
C 5P-1755 Shim 1 Start By:
Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install".
Remove the rocker shaft and pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Push Rods - Remove".
Remove the electronic unit injector. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove".
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, NENG2500, "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 at all times.
Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
Illustration 1 g02088484
Remove bolts (1). Disconnect exhaust manifold (2). Remove bolts (11). Disconnect inlet manifold (12).
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 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.
Refer to special instruction M0069244 for engine cleaning requirements before removing the head.Note: Failure to comply will result in damage to the engine and its related components.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).