842300 Volvo.Penta Disc clutch

* Serial engine numbers are assigned to the engines in manufacturing sequence. Every engine has its own number. These numbers are required for registration and related inspection of the vehicle. *An engine name plate indicates the following item.* Engine modelHow To Read This Manual
Structure of This Shop Manual
Terminology
Tightening Torques
* Tightening torques are broadly classified as follows:* Bolts and nuts for which tightening torques are specified regardless of installation location are referred to as "standard" bolts and nuts, and their tightening torques are referred to as "standard" tightening torques. (Standard tightening torques are specified in accordance with the sizes and materials of threaded parts.) Identify standard bolts and nuts by comparing them with the following standard tightening torque table. The tightening torques for standard bolts and nuts are shown in this table, and not particularly shown in the text.* The tightening torque for any bolt or nut that is not subject to a standard tightening torque or cannot be identified from the following table is shown in the text.* Any bolt or nut indicated as "wet" must be tightened in a wet condition (with engine oil or grease applied). Any other item must be tightened in a dry condition.Standard tightening torque table
* Use the specified bolts and nuts. Except where otherwise specified, tighten them to the torques shown in the following table.* The threads and seating surfaces must be dry.* If a mating nut and a bolt (or stud bolt) have different strength classifications, tighten to the torque shown for the bolt.(1) Hexagon head bolts and stud bolts (Unit: N m {kgf m} (2) Hexagon head flange bolts (Unit: N m {kgf m} (3) Hexagon nuts (Unit: N m {kgf m} (4) Hexagon flange nuts (Unit: N m {kgf m} (5) Tightening torque for general-purpose flare nut (Unit: N m {kgf m} (6) Tightening torque for general-purpose air piping nylon tube (DIN type) (Unit: N m {kgf m} (7) Tightening torque for general-purpose air piping nylon tube (SAE type) (Unit: N m {kgf m} Units
* Tightening torques and other parameters are given in SI* units with metric units added in brackets { }/ Values in engine specifications, performance curves, and other items taken from official approval documents are given only in metric units. How To Read This Manual
General Work
Part Measurement Methods
* Pay close attention to the following points when measuring parts.Shaft-to-hole clearance measurement, and good/bad evaluation
* Where a shaft-to-hole clearance is specified as a service standard, measurement and good/bad evaluation must be performed as follows:* Choose at least two measurement locations along the length of the shaft. Add measurement locations depending on the length of the shaft. The following example assumes three measurement locations.* At each measurement location (a, b, and c), measure the shaft diameter and hole diameter in two directions perpendicular to each other. Note the smaller shaft measurement (min) and larger hole measurement (max) at each measurement location.Shaft: da min, db min, dc minHole: Da max, Db max, Dc max* For each of the three measurement locations (a, b, and c), subtract the smaller (noted) shaft diameter from the larger (noted) hole diameter to determine the clearance.Clearance a= Da max - da minClearance b= Db max - db minClearance c= Dc max - dc min* Compare the biggest of the clearances with the service standard (standard value or limit). If the clearance exceeds the service standard (standard value or limit), replace the defective part (the shaft or the part containing the hole).Example:If clearance a > clearance b > clearance c, then clearance a is the biggest one (clearance max).If clearance max > service standard (standard value or limit), then the clearance is not acceptable.Shaft deflection and bend
* The deflection of a shaft is the indication given by a needle of a dial gauge after one rotation of the shaft. Half of the deflection is the extend of bend.Measurement of springs
* To take a load measurement with a compression spring, use a spring tester to measure the load with the spring at its installed length as illustrated. To take a load measurement with an extension spring, use a spring balance to measure the load with the spring at its installed length as illustrated.* To measure the squareness of a compression spring, place the spring on a surface plate, standing against an engineer's square. Turn the spring once. Measure the clearance between the end of the spring and the square where it is greatest. This value is the squareness.Evaluation of Oil Leakage
* Specific instructions for inspecting and evaluating oil leakage are given in certain inspection procedures. In general, however, the following conditions are used in criteria:* Externally dry: Seals, gaskets, and joints are complete and externally dry.* Oozing: Seals, gaskets, and surrounding areas are moist.* Collecting: Oil droplets have accumulated, but there is no visible dripping.* Dripping: Oil is dripping in sufficient quantity to make a mark on the floor. Precautions For Maintenance Operation
* Before performing service operations, inquire the operating conditions and the customer's demand on site and record the necessary information to judge the condition of the engine correctly. Based on that information, perform the efficient and effective maintenance.* Check the location of the fault, and identify its cause. Based on your findings, determine whether parts must be removed or disassembled. Then, follow the service procedure given in this manual.General Precautions
* The service operations should be performed on a flat place. Prepare all the general and special tools necessary for the job.
* Special tools must be used wherever specified in this manual. Do not attempt to use other tools since they could cause injuries and/or vehicle damage.
* Take extreme care when removing/installing heavy items such as engine. When lifting heavy items using a cable, etc., observe the following precautions. * Identify the mass of the item being lifted. Use