3803311 Volvo.Penta Cylinder head

Illustration 1 g00295602
Connecting Rod And Bearings
Naturally Aspirated Engines
(1) Inside diameter of rod for bearing ... 38.89 to 38.92 mm (1.531 to 1.532 inch) (2) Outside diameter of bearing for piston pin ... 38.94 to 39.03 mm (1.535 to 1.536 inch)Inside diameter of bearing for piston pin after reaming ... 34.940 to 34.960 mm (1.3758 to 1.3765 inch)Clearance between small end bearing and piston pin ... 0.020 to 0.043 mm (.0008 to .0017 inch) (3) Distance between center of piston pin and center of crankshaft bearing ... 219.05 to 219.10 mm (8.624 to 8.626 inch) (4) Bearings are available for remachined journals of the crankshaft which have the following undersize dimensions: 0.25 mm (.010 inch) 0.51 mm (.020 inch) 0.76 mm (.030 inch)Shell thickness ... 1.835 to 1.842 mm (.0723 to .0726 inch)Width of connecting rod bearing ... 31.62 to 31.88 mm (1.245 to 1.255 inch)Bearing clearance ... 0.035 to 0.081 mm (.0014 to .0032 inch) (5) Inside diameter of rod for bearing ... 67.210 to 67.220 mm (2.6460 to 2.6465 inch) (6) Connecting rod cap with nuts and bolts Tighten the nuts for the connecting rod to the following torque: ... 125 N m (92 lb ft)Connecting rod cap with bolts onlyTighten the bolts for the connecting rod to the following torque: ... 155 N m (114 lb ft)Turbocharged Engines
(1) Inside diameter of rod for bearing ... 42.07 to 42.09 mm (1.656 to 1.657 inch) (2) Outside diameter of bearing for piston pin ... 42.160 to 42.190 mm (1.6600 to 1.6613 inch)Inside diameter of bearing for piston pin after reaming ... 38.120 to 38.140 mm (1.5008 to 1.5015 inch)Clearance between small end bearing and piston pin ... 0.020 to 0.043 mm (.0008 to .0017 inch) (3) Distance between center of piston pin and center of crankshaft bearing ... 219.05 to 219.10 mm (8.624 to 8.626 inch) (4) Bearings are available for remachined journals of the crankshaft which have the following undersize dimensions: 0.25 mm (.010 inch) 0.51 mm (.020 inch) 0.76 mm (.030 inch)Shell thickness ... 1.835 to 1.844 mm (.0723 to .0726 inch)Width of connecting rod bearing ... 31.55 to 31.88 mm (1.240 to 1.255 inch)Bearing clearance ... 0.030 to 0.081 mm (.0012 to .0032 inch) (5) Inside diameter of rod for bearing ... 67.210 to 67.220 mm (2.6460 to 2.6465 inch) (6) Connecting rod cap with nuts and bolts Tighten the nuts for the connecting rod to the following torque: ... 125 N m (92 lb ft)Connecting rod cap with bolts onlyTighten the bolts for the connecting rod to the following torque: ... 155 N m (114 lb ft)Note: If piston cooling jets are installed, the piston and the connecting rod assembly must be turned when the piston and rod assembly are installed. Turning the piston and connecting rod assembly will prevent the connecting rod from hitting and damaging the piston cooling jet. When the connecting rod has passed the piston cooling jet, turn the connecting rod until the arrow or "Front" mark on the top of the piston is toward the front of the engine.Type 2 Engines and 7BJ Engines
Note: For a complete description of Type 1 and Type 2 engines, refer to the Specifications Module, "Engine Design" for more information.The piston height is controlled by the length of the connecting rod. Connecting rods are supplied in six grades of length. The different grades of length are manufactured by machining the hole in the piston pin bearing in an off-center position. The different grades of length are created by the following method:
Machining the center of the hole in the piston pin
Machining the center of the hole in the bearing
If the connecting rod is replaced, ensure that the same grade of length as the original connecting rod is used.However, if the crankshaft or the cylinder block is replaced, the required grade of length of the connecting rods may change.A correct grade of length of a connecting rod can be ordered for replacement. The connecting rod includes the piston pin bearing. The piston pin bearing is machined in order to create the correct grade of length. The piston pin is installed in the connecting rod at the factory. Table 1 provides the specifications for the grade of length.Note: The length of the connecting rod is determined by the following method: The bearing for the crankshaft journal must be removed and the piston pin must be installed. The original grade of length of the connecting rod is determined when the original piston pin is installed.Connecting rods are color coded. The color code is a reference for the length (Y) of the connecting rod. Refer to Table 1 for the different lengths of connecting rods.
Illustration 2 g00915056
Table 1
Grade of Length Color Length of the Connecting Rod
"F" Red 165.728 to 165.761 mm (6.5247 to 6.5265 inch)
"G" Orange 165.682 to 165.715 mm (6.5229 to 6.5247 inch)
"H" White 165.637 to 165.670 mm (6.5211 to 6.5229 inch)
"J" Green 165.591 to 165.624 mm (6.5193 to 6.5211 inch)
"K" Purple 165.545 to 165.578 mm (6.5175 to 6.5193 inch)
"L" Blue 165.499 to 165.532 mm (6.5157 to 6.5175 inch) If a piston pin bearing requires replacement but the connecting rod does not require replacement, a new piston pin bearing can be ordered. This bearing is partially finished. The hole in the bearing must be machined off-center to the correct distance in order to create a connecting rod assembly that is the correct grade of length.Refer to the Testing and Adjusting manual for the following procedures:
Determine the length of the connecting rod.
Determine the distortion of a connecting rod.
Replace the piston pin bearing.Turbocharged Engines
Serrated Connecting Rods and Flat Connecting Rods
Illustration 3 g00295602
Connecting Rod And Bearings
(1) Inside diameter of rod for bearing ... 43.01 t