volvo — Volvo Penta Workshop Manual Model# 2001 2002 2003(T)

3 . Use mandrel p/n 5218 to press out the valve guides . Oil the new valve guides externally and use mandrel p/n 884559 to install them . Press down the mandrel all the way down to the cylinder head . Ream the valve guides if necesary . THE CYLINDER HEAD 1 . Remove the "collets" and valve springs using a valve bow . Remove the valves . Remove t he valve stem seals . Place the valves in the proper sequence in a valve stand . Valve seats and valves 4 . Mill or ream the valve seats . The angle (C) should be 45° (for 2003T, 30° for the inlet valve) . The sealing surface's width Valve guides 2 . Check the valve guide wear by inserting anew valve stem into the guide .

Measure the play using a dial indicator . If necessary, replace the valve guides . Wear limits : Inlet valve, max play . . . . . . . . . . . . . . . 0 .15 mm (0 .0059 in) Exhaust valve, max play . . . . . . . . . . . . 0 .15 mm (0 .0059 in) (B) should be 1 ±0 .1 mm (0 .039±0 .0039 in) . Grind the valves in a valve grinding machine . The angle (D), see Tech . data . If the disc thickness after grinding is less than 1 .0 mm (0 .039 in) for naturally aspirated engines or 0 .8 mm (0.031 turbocharged engines, the valves must be scrapped . Valves with bent stems, or if the measurement (A) exceeds 2 .5 mm (0 .098 in) for in) must also be scrapped .

Grind the valve tip towards the rockers if necessary . Lap in the valves using valve grinding paste and check the contact area with marking dye .