382163 Volvo.Penta Cover

Table 1
Required Tools
Tool Part Number Part Description Qty
B 1U-9895 Crossblock 1
3H-0465 Push-Puller Plate 2
8F-6123 Bolt 2
0S-1575 Bolt 4
3B-1925 Washer 4
C 8T-0455 Liner Projection Tool Group 1
D 2P-8260 Cylinder Liner Installer 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Cylinder Liner Projection
Illustration 1 g01208517
Install a new gasket for the spacer plate and install the spacer plate.
Do not install the O-ring seals or the filler band on the cylinder liner. Position the cylinder liner in the cylinder bore.
Secure the spacer plate and the cylinder liner in position according to the following procedure:
Install bolts (4) and the washers around the cylinder liner.
Tighten bolts (4) evenly to a torque of 95 N m (70 lb ft).
Install Tooling (B). Ensure that Tooling (B) is in position at the center of the cylinder liner. Ensure that the surface of the cylinder liner is clean. Tighten the bolts on Tooling (B) evenly to a torque of 70 N m (50 lb ft).
Use Tooling (C) to measure the liner projection.
Place the gauge body on the spacer plate near the liner flange. Gauge should read zero. Position the gauge body so that the point is on the outer ring of the liner flange. The gauge will read the liner projection. Measure four equally distant points around the liner flange. Note: If the measurements around the liner are different, rotate the liner to a different position within the bore. If the liner projection is not within specifications, move the liner to a different bore. Inspect the top face of the cylinder block. Measure the cylinder block bore for the liner. If the bore is too shallow, the bore may require rework.
The liner projection must be 0.059 to 0.199 mm (0.0023 to 0.0078 inch). The maximum acceptable difference between the high measurements and the low measurements is 0.05 mm (0.002 inch).
Illustration 2 g00578874
If the liner projection is not 0.059 to 0.199 mm (0.0023 to 0.0078 inch), measure the thickness of the following items: (5) Spacer plate ... 12.31 0.025 mm (0.490 0.0010 inch) (6) Spacer plate gasket ... 0.21 0.025 mm (0.010 0.0010 inch) (7) Cylinder liner flange ... 12.65 0.020 mm (0.500 0.0010 inch)
When the liner projection is correct, make alignment marks on the liner and the cylinder block.
Remove Tooling (B) and Tooling (C). Remove the liner, the spacer plate, and the gasket for the spacer plate. Install the Cylinder Liner
Illustration 3 g01004731
Apply liquid soap on the grooves for O-ring seals (1) and on O-ring seals (1). Install O-ring seals (1) on cylinder liner (2). Also, coat the cylinder block bore for cylinder liner (2) with liquid soap.
Dip filler band (3) in clean engine oil. Immediately install filler band (3) onto cylinder liner (2).
Immediately install cylinder liner (2) before filler band (3) can expand. Ensure that the marks that are on cylinder liner (2) and the cylinder block are aligned.
Illustration 4 g01256602
Use Tooling (D) to press the cylinder liner into the cylinder block. End By:
Install the pistons and connecting rods.