20412423 Volvo.Penta Charge air pipe

Inspection points1. Main bearing installation (1) Install the upper halves of the main bearings in the cylinder block and the lower halves in the main bearing caps so lower halves in the main bearing caps so their tabs fit into the notches in the cylinder block and the main bearing caps.(2) Install the flanged bearing in the No. 3 journal.(3) Lightly lubricate the inside surfaces of the bearings with engine oil.
Installing main bearings2. Crankshaft installation (1) Clean the crankshaft with cleaning solvent and blow dry with compressed air. (2) Fasten a hoist to the crankshaft and hold it in horizontal position. Carefully put the crankshaft in position in the cylinder block.(3) Lightly lubricate the crankshaft journals with engine oil.
Installing crankshaft3. Main bearing cap installation (1) Coat the mating surfaces of the rear bearing cap and cylinder block with Three Bond 1212. (2) Install the main bearing caps in position. Make sure the number (arrow head) on the main bearing cap is toward the front of the engine.(3) Tighten the main bearing cap bolts finger tight only.
Main bearing caps installed
Install the front and rear bearing caps in position so their end faces are even with the end faces of the cylinder block.
Installing front and rear bearing caps(4) Tighten the bolts holding the main bearing caps in steps to the specified torque.
Tightening bolts holding main bearing caps(5) Make sure the crankshaft rotates freely without binding or catching.(6) Measure the end play for the crankshaft. Make reference to "End play measurement for crankshaft" (page 42). If the end play is incorrect, loosen the bolts holding the main bearing caps once and tighten them again.
Checking crankshaft for rotation4. Side seal installation (1) Coat the side seals with Three Bond 1212.(2) Insert the side seals between the cylinder block and the front and rear caps and push in them by hand as far as possible, with their rounded side toward the outside of the cylinder block.
Side seals(3) Using a flat plate, push the seals into position, taking care not to bend them.
Installing side seals5. Piston assembling to connecting rod(1) Set Piston Setting Tool (31A91-00100) (special tool) in a hydraulic press.(2) Put the connecting rod on the Tool and lubricate the bore in the rod for the piston pin with engine oil.
Connecting rod on Piston Setting Tool(3) Put the piston in position on the connecting rod, making sure the model identification on the rod is on the same side as the arrow head on the top of the piston. Put the piston pin in position.
Installing piston pin(4) Insert the push rod of the Tool into the bore in the piston for the piston pin and press the pin with the press.
Observe the indicator of the press when pressing the piston pin. If the force of the press is ready to exceed 50 kgf (110 lbf) [490 N], stop pressing the pin and check the bores in the piston and connecting rod for alignment.
Pressing piston pin(5) After assembling the piston and connecting rod, make sure the connecting rod moves freely.
Checking piston and connecting rod6. Piston ring installation Using a piston ring pliers, install the piston rings on the piston. a) The piston rings must be installed with the side that has the mark "T" toward the top of the piston.b) The oil ring must be installed with the ring end gap 180° apart from the coil spring joint.
Piston rings
Oil ring7. Piston and connecting rod installation(1) Lubricate the piston and piston rings with engine oil.(2) Move the piston rings on the piston so that the end gaps are apart from a direction parallel to, or transverse to, the piston pin. (3) Install the connecting rod bearing (upper half) to the rod, making sure the tab in the back of the bearing is in the notch of the connecting rod. (4) Turn the crankshaft until the crankpin for the piston and connecting rod to be installed is at the top center. (5) Hold the piston and connecting rod with "FRONT" mark (arrow head) on the top of the piston toward the front (timing gear case side) of the engine.
Relative location of piston ring end gaps(6) Using a piston guide (commercially available), put the piston and connecting rod into the cylinder from the top of the cylinder block.
Do not hit the piston with a hammer to install the piston and connecting rod. This will put force on the piston and connecting rod and cause damage to the piston rings and crankpin.
Installing piston and connecting rod8. Connecting rod cap installation (1) Push the piston into position until the big end of the connecting rod is put into position over the crankpin. Then turn the crankshaft 180° while pushing on the top of the piston.(2) Install the lower half of the connecting rod bearing in the connecting rod cap, making sure the tab in the back of the bearing is in the notch of the cap.(3) Install the bearing cap to the connecting rod.
Installing connecting rod cap a) Make sure the number on the cap is the same as the number on the connecting rod.b) In case of a new connecting rod having no cylinder number, install the cap to the rod with the notches on the same side. (4) Tighten the connecting rod cap nuts in steps to the specified torque. (5) Check the thrust clearance for the connecting rod big end.
Tightening connecting rod cap nuts9. Oil screen installation (1) Lay the cylinder block with the bottom (oil pan side) up.(2) Install the oil screen in position. The oil screen must be installed in position so that it is below the oil level line and away from the oil pan.
Installing oil screen10. Oil pan installation (1) Clean the mating surfaces of the oil pan and cylinder block and coat them with Three Bond 1207C.