Volvo Penta — Pressure-testing a cylinder head
Testing & diagnosis
From a Volvo Penta service manual — check it applies to your exact model before use.
Browse Volvo Penta generators & specs →
Before you start
- Follow relevant safety regulations
- Do not lean over the expander screws
Procedure
- 100-series: fit clamp 6685 and expander screws 2124 (2x); 120-series: fit connecting washer 6683 and expander screws 2124.
- Do not overtighten the wing nuts, which would damage the rubber gaskets.
- Check that the reducing valve wheel is unscrewed and connect the hose to the cylinder head.
- Immerse the cylinder head in a water tank at approx. 70 C (158 F).
- Connect the pressure-testing device and open the cock; raise pressure to 50 kPa and hold for 1 minute.
- Raise the pressure to 150 kPa, lock the wheel and close the cock.
- After 1-2 minutes check if the pressure has fallen or air bubbles are visible.
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- 50 kPa held 1 minute
- 150 kPa test pressure
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.