21268949 Volvo.Penta Alternator kit

Illustration 1 g00365332
Instructions for 1U-6431 Piston Ring Groove Gauge Connecting Rods And Pistons
Use the 7M-3978 Ring Expander in order to remove the piston rings. Use the 7M-3978 Ring Expander in order to install the piston rings.Use the 5P-3526 Piston Ring Compressor in order to install the pistons into the cylinder block.Tighten the connecting rod nuts in the step sequence that follows:
Apply 4C-5593 Anti-Seize Compound to the threads of the bolts and the contact surfaces of the bolt head.
Tighten all bolts to the following torque.Torque for bolts ... 90 8 N m (66 6 lb ft)
Put an alignment mark on each cap and bolt.
Tighten the bolts from the mark to the following value.Angle from the mark. ... 90 5 degreesConnecting Rod Bearings
The connecting rod bearings fit tightly in the bore in the rod. If the bearing joints or backs are fretted, check the bore size. This can be an indication of wear because of a loose fit.Connecting rod bearings are available with 0.63 mm (0.025 inch) and 1.27 mm (0.050 inch) smaller inside diameter than the original size bearing. These bearings are for crankshafts that have been ground.Main Bearings
Main bearings are available with a larger outside diameter than the original size bearings. These bearings are available for the cylinder blocks with the main bearing bore that is made larger than the bores' original size. The size that is available has a 0.63 mm (0.025 inch) outside diameter that is larger than the original size bearings.Cylinder Block
If the main bearing caps are installed without bearings, the bore in the block for the main bearings can be checked. Tighten the nuts that hold the caps to the torque that is shown in the Specifications. Alignment error in the bores must not be more than 0.08 mm (0.003 inch). Refer to the Special Instruction, SMHS7606 for the use of the 1P-4000 Line Boring Tool Group for the alignment of the main bearing bores. The 1P-3537 Dial Bore Gauge Group can be used to check the size of the bores. The Special Instruction, GMGO0981 is with the group.
Illustration 2 g00294303
1P-3537 Dial Bore Gauge Group Projection Of Cylinder Liners
Table 1
Specifications    
Liner Projection    
0.025 to 0.152 mm (0.001 to 0.006 inch)    
Maximum Variation In Each Liner    
0.051 mm (0.0020 inch)    
Maximum Average Variation Between Adjacent Liners    
0.051 mm (0.0020 inch)    
Maximum Variation Between All Liners    
0.102 mm (0.0040 inch)    
Illustration 3 g00557687
Holding The Top Plate To The Cylinder Block (Typical Example) (1) 3H-0465 Push Puller Plate (2) 1P-2396 Adapter Plate (3) 2F-0126 Seal (4) Top plate
Illustration 4 g00557691
Reworking Of The Old Spacer Plate (5) SectionsNote: On engines with aluminum spacer plates, use care in obtaining liner projection measurements to prevent marring the surface. Use copper washers with the spacer plate bolts in order to prevent damage to the spacer plate. Do not use hardened steel washers. Follow the correct procedure when tightening the spacer plate bolts.
Be sure that the top plate (4) and the cylinder liner flange are clean. Install a new top plate gasket, but do not install liner seals when this check is made.To increase the accuracy of liner projection measurements, cut figure eight sections from an old spacer plate. Install the figure eight sections below the spacer plate bolts. This helps to prevent damage to engine parts. The figure eight sections are the center ribs from a scrapped 2W-8601 Spacer Plate. Refer to Illustration 4. The top radius and the bottom radius of the figure eight sections should coincide with the radii of the washers. Note: To keep the movement of the bolts and the washers to a minimum, install two bolts with washers on each side of each cylinder liner.
Use 0S-1575 Bolt and two seals (3) on each bolt in order to hold the top plate (4) to the cylinder block. Install two bolts with seals (3) on each side of the cylinder liner. Tighten the bolts in the following manner:
Tighten the bolts to 14 N m (10 lb ft).
Tighten the bolts to 35 N m (25 lb ft).
Tighten the bolts to 70 (50 lb ft).
Tighten the bolts to 95 N m (70 lb ft).
Use the following parts in order to hold the liner:puller plate (2), three plates (1), 8B-7548 Push-Puller Tool Group and two 2H-3749 Bolt
Tighten the bolts in the following manner:
Tighten the bolts to 7 N m (5 lb ft).
Tighten the bolts to 20 N m (15 lb ft).
Tighten the bolts to 35 (25 lb ft).
Tighten the bolts to 70 N m (50 lb ft).The distance from the bottom edge of 8B-7548 Push-Puller Tool Group to the top plate must be equal on both sides of the cylinder liner.
Use a 8T-0455 Liner Projection Tool Group to measure the liner projection. Refer to Special Instruction, SMHS7727 for more information on the measurement procedures.
Set the dial indicator to zero.Note: If the liner projection changes, turn the liner to a new position within the bore. If the liner projection is not correct, move the liner to a different bore.Note: When the liner projection is correct, put a temporary mark on the liner and the top plate. This allows the liner to be installed in the correct position.
The liner projection must be 0.03 to 0.15 mm (.001 to .006 inch). Make the measurement to the top of the liner flange. Do not make the measurements to the inner ring. The maximum difference between the measurements that are made at four places around each liner is 0.05 mm (.002 inch). The average projection of liners next to each other must not be more than 0.05 mm (.002 inch). The maximum difference in the average projection of the cylinder liners under one cylinder head must not be more than 0.10 mm (.004 inch).The contact face of the cylinder block can be machined with use of the 8S-3140 Co