822621 Volvo.Penta End cover

Table 1
Required Tools
Tool Part Number Part Description Qty
A 9S-9082 Engine Turning Tool 1
B(1) 5P-3526 Piston Ring Compressor 1
B(2) 200-3914 Piston Ring Compressor 1
C 8T-3052 Degree Wheel 1
(1) For use with the C15 engine.
(2) For use with the C18 engine.Start By:
Remove the cylinder head.
Remove the engine oil pump.
Remove the piston cooling jets.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g00998389
Use Tooling (A) to rotate the crankshaft until the piston is at the bottom center.
Remove the carbon ridge from the top inside surface of the cylinder liner.
Inspect the connecting rod and connecting rod cap for the proper identification mark. The connecting rod and the connecting rod cap should have an etched number on the side. The number should match the cylinder number. Mark the connecting rod and the connecting rod cap, if necessary.Note: Do not stamp the connecting rod assembly. Stamping or punching the connecting rod assembly could cause the connecting rod to fracture.
Remove bolts (1) and connecting rod bearing cap (2). Push the connecting rod until the piston rings are out of the cylinder liner.
Illustration 2 g00998390
Remove piston (3) and the connecting rod from the cylinder liner.Note: Be careful not to damage the cylinder liner or the crankshaft journal during the removal of the piston and the connecting rod.Installation Procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Install the connecting rod bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check". Apply clean engine oil on the connecting rod bearings for final assembly.
Apply clean engine oil to the cylinder liner bore, to the piston rings, and to the outer surface of the piston.Note: The piston and connecting rod are matched to a specific cylinder. Ensure that the connecting rod and pistons are installed in the correct cylinder.
Use Tooling (A) to rotate the crankshaft until the connecting rod journal is at the bottom center.
Illustration 3 g01048560Note: Be careful not to damage the cylinder liner, the crankshaft journal during installation of the piston and the connecting rod.
Use Tooling (B) to install piston (3) and the connecting rod in the cylinder liner.Note: Install the connecting rod so that the bearing tab is on the side of the piston cooling jet.
Install the upper connecting rod bearing in the connecting rod.Note: Ensure that the connecting rod bearing is installed so that the bearing tab fits into the notch in the connecting rod.
Lubricate the connecting rod bearing with clean engine oil and pull the connecting rod onto the crankshaft journal.
Install the lower connecting rod bearing in the connecting rod bearing cap.Note: Ensure that the connecting rod bearing is installed so that the bearing tab fits into the notch in the connecting rod.
Illustration 4 g01016640
Position connecting rod bearing cap (2) on the connecting rod.Note: Ensure that the number on the side of the connecting rod bearing cap is on the same side as the number on the connecting rod. The bearing tabs of the connecting rod bearing cap and the connecting rod are on the side of the piston cooling jet.
Lubricate the threads of bolts (1) with clean engine oil and install bolts (1).
Tighten bolts (1), as follows:
Tighten Bolt (A) and Bolt (C) to a torque of 70 4 N m (52 3 lb ft).
Tighten Bolt (B) and Bolt (D) to a torque of 70 4 N m (52 3 lb ft).
Turn Bolt (B) and Bolt (D) for an extra 60 5 degrees (1/6 turn).Note: If Tooling (C) is not used, place an index mark on each bolt.
Tighten Bolt (A) and Bolt (C) to a torque of 70 4 N m (52 3 lb ft).
Turn Bolt (A) and Bolt (C) for an extra 60 5 degrees (1/6 turn).Note: If Tooling (C) is not used, place an index mark on each bolt.
Rotate the crankshaft to ensure that the crankshaft turns freely.End By:
Install the piston cooling jets.
Install the engine oil pump.
Install the cylinder head.