Volvo Penta — Cylinder head, leakage check

Testing & diagnosis

From a Volvo Penta service manual — check it applies to your exact model before use.

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Procedure

1. Fit cylinder head in engine stand.
2. Remove valve yoke and exhaust manifold.
3. Remove thermostat housing and piston thermostat.
4. Wash and clean cylinder head.
5. Fit sealing washers and plugs.
6. Attach leakage check tool 9996662 to pneumatic system.
7. Set reducing valve to 100 kPa; pressure must not sink for two minutes.
8. Lower cylinder head into water bath at 70°C.
9. Open pneumatic system, set 50 kPa, maintain 1 minute.
10. Raise pressure to 150 kPa, lock valve, close cock.
11. Check no air pressure drop and no bubbles.
12. Move test equipment to thermostat housing nipple and repeat.
13. Remove cylinder head from water bath, dry with compressed air.
14. Remove sealing washers and refit pipe connections.
15. Fit new piston thermostat seal and thermostat housing.

Source: Volvo Penta service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.

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