835122 Volvo.Penta Bracket

Illustration 1 g00365332
Instructions for the 1U-6431 Piston Ring Groove Gauge Some engines have piston grooves and rings of the keystone design (taper). The 1U-6431 Piston Ring Groove Gauge is available to check the top two ring grooves in the piston. For the correct use of the gauge, refer to the instruction card that is with the gauge.Pistons with Straight Sides in the Ring Grooves
A 5P-3519 Piston Ring Groove Gauge is available for checking piston ring grooves with straight sides. Refer to Special Publication, SEBF8049, "Guideline for Reusable Parts (Pistons)" for instructions.Connecting Rods and Pistons
Use the 7S-9470 Piston Ring Expander to remove or install piston rings.Use the 5P-3525 Piston Ring Compressor in order to install pistons into the cylinder block.Tighten the connecting rod nuts in the following sequence:
Before you install the connecting rod bolts, lubricate the bolt threads and the seating faces of the caps with 6V-4876 Lubricant .
Tighten the bolts to the following torque. 40 4 N m (30 3 lb ft)
Place an alignment mark on each cap and on each bolt head.
Tighten each bolt for an additional 90 5 degrees (1/4 of a turn).Connecting Rod Bearings
The connecting rod bearings must fit tightly into the bore in the rod. A loose fit is an indication of wear. If the bearing joints or the backs are worn, check the bore size. If the matching joints are fretted, check the bore size.Note: Connecting rod bearings are available with undersized inside diameters. The inside diameters are undersize by the following dimensions:0.25 mm (.010 inch), 0.51 mm (.020 inch) and 0.76 mm (.030 inch). If the undersized connecting rod bearings are used for repair, the crankshaft must be machined.Main Bearings
Main bearings are available in different sizes. The different sizes are used for repair. Some main bearings have undersized inner diameters. Some main bearings have oversized outer diameters. Some main bearings have both undersized inner diameters and oversized outer diameters. These bearings are available for cylinder blocks and/or crankshafts that need to be machined in order to be repaired.Note: Refer to the Parts Manual for additional information on Main Bearings and Journals.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, "Cylinder Block". Alignment error in the bores must not be more than 0.08 mm (.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 g00285686
1P-3537 Dial Bore Gauge Group Projection Of Cylinder Liners
Table 1
Tools Needed     Quantity    
8B-7548     Push-Puller Tool Group     1    
3H-0465     Push Puller Plate     2    
8F-6123     Bolt (1)     2    
1S-0379     Washer (3/4 inch Copper)     4    
0S-1575     Bolt (2)     4    
8T-0455     Liner Projection Tool Group     1    
( 1 ) Bolt size is 3/4 16 NF and 140 mm (5.5 inch).
( 2 ) Bolt size is 3/4 16 NF and 76 mm (3.0 inch).
Make sure that the top surface of the following components are clean and dry:
Cylinder block
Cylinder liner bores
Spacer plates
Cylinder liner flanges
Illustration 3 g00285687
Measuring the Liner Height Projection (1) 3H-0465 Push Puller Plate. (2) Dial Indicator. (3) 1P-2402 Gauge Body. (4) 0S-1575 Bolt. (5) Spacer plate. (6) 8B-7548 Push-Puller Tool Group .
Install a new gasket and spacer plate (5) on the cylinder block.
Install the cylinder liners in the cylinder block without seals or without bands.
Hold the spacer plate and the cylinder liner in position according to the following procedure:
Install four 0S-1575 Bolt (4) and washers around each cylinder liner. Tighten the bolts evenly to a torque of 95 N m (70 lb ft).Ensure that the surface of the cylinder liner is clean.
Install the following items:
The 8B-7548 Push-Puller Tool Group (6)
The 3H-0465 Push Puller Plate (1)
Two 8F-6123 Bolts Determine that the 8B-7548 Push-Puller Tool Group is in the proper position at the center of the cylinder liner.
Check the distance of the edges from the bottom of the 8B-7548 Push-Puller Tool Group (6) to the top of the spacer plate. The distance on each end of the 8B-7548 Push-Puller Tool Group must be equal.
Use the 8T-0455 Liner Projection Tool Group to measure the cylinder liner projection.
Mount the dial indicator (2) in the 1P-2402 Gauge Body (3). Use the back of the 1P-5507 Gauge Block to zero the dial indicator (2).
The cylinder liner projection must be 0.033 to 0.175 mm (.0013 to .0069 inch). Make the measurement to the outer flange of the cylinder liner. Do not make the measurement to the inner ring. The maximum difference between the high measurements and the low measurements that are made at four places around each cylinder liner should be 0.05 mm (.002 inch).Note: If the cylinder liner projection changes around the cylinder liner, turn the cylinder liner to a new position within the bore. If the cylinder liner projection is not within specifications, move