20412484 Volvo.Penta Fan

2. Turn the crankshaft until two pistons are at bottom center. Remove two nuts (2) and connecting rod cap (1) from the connecting rod.3. Put tape or pieces of rubber hose over the threads of the connecting rod bolts. This will prevent damage to the crankshaft during removal of pistons.
Do not let the connecting rods hit the crankshaft during removal and installation of the pistons. Damage to the crankshaft journal can cause an early rod bearing failure.
4. Push the piston and connecting rod away from the crankshaft until the piston rings are above the cylinder liner. Remove the piston (3) and the connecting rods from the engine.5. Keep each connecting rod cap with its respective connecting rod and piston. Put identification on each connecting rod as to its location in the engine for use at assembly of the engine.Do Steps 2 through 5 for the remainder of the pistons.Install Pistons
1. Turn the crankshaft until the bearing journals for the piston to be installed are at bottom center.2. Put clean engine oil on the crankshaft journals and on the inside of the cylinder liners. Put clean engine oil on the piston rings and connecting rod bearings.3. Move the rings on the piston until the ring openings are approximately 90° apart.
Never install the ring compressor on the piston unless the cylinder liner is used as a guide. Damage to the piston rings can be the result.
4. Put ring compressor (A) in position on the cylinder liner. Put the connecting rod and piston in position in the same cylinder liner from which it was removed and into the ring compressor. Make sure the "V" mark on the piston is in alignment with the "V" mark on the cylinder block. If a replacement rod or piston is to be used, the bearing tab notch on the rod must be on the same side of the assembly as the cutout (depression) on the top of pistons.5. Push the piston into place as the connecting rod is put in position on the crankshaft. 6. Put clean engine oil on bearings, bolt threads and surfaces of the nuts that make contact with the connecting rod caps. Put caps (1) in position on the connecting rods and install the nuts. Tighten the nuts to a torque of 30 3 lb.ft. (40 4 N m). Put a mark on each nut and the end of each bolt. Tighten the nuts 90° more.
Do not use an impact wrench to tighten the rod bolts the additional 90°. When connecting rod caps are installed, make sure the number on the side of the cap is next to and respective with the number on the side of the connecting rod.
7. Follow the same above precedure for installation of the remainder of the pistons.END BY:a) install oil pan plateb) install cylinder headDisassemble Pistons
START BY:a) remove pistons 1. Remove the rings from the piston with tool (A).2. Remove the bearings from the connecting rod cap. 3. Remove retaining rings (3), pin (1) and connecting rod (2) from the piston.4. See USE OF PISTON PIN BEARING REMOVAL AND INSTALLATION TOOLS, SPECIAL INSTRUCTIONS, Form No. SMHS7295-02 for move information of removal and installation of piston pin bearings. 5. Heat the connecting rod to a temperature of 350 to 500°F (176 to 260°C). Put 6V3029 Spacer (11) in the base plate. Put the connecting rod on the base plate of tooling (B).6. Put the connecting rod piston pin bearing end in the center of the port assembly of tooling (B). Install pin (6) in the center of the bore for the connecting rod bearings.7. Install 6B2049 Adapter (9). Put the hole in the adapter in alignment with the hole in the base plate of tooling (B).8. Install clamp bar (10) and clamp pin (7).9. Install new piston pin bearing (5) on adapter (9). The old bearing is pushed out by tooling (B) as the new bearing is installed.10. Put 5P8645 Adapter (8) in position as shown with the taper side down. The piston pin bearing joint must be in alignment with the hole in adapter (9) and the base plate of tooling (B).11. Put pusher (4) on adapter (8).12. Use tooling (B) to push the new piston pin bearing into the connecting rod until adapter (8) of tooling (B) makes full contact with the connecting rod surface.13. Remove the connecting rod and the old piston bearing from tooling (B).14. Check the piston pin bearing bore diameter after the bearing is installed. The correct dimension is 1.7012 .0003 in. (43.210 0.008 mm).Assemble Pistons
1. Install the connecting rod (4) in the piston with the bearing tab groove (slot) (1) on the same side as the cutout (depression) (3) on the head of the piston.2. Install piston pin (2) and retaining rings (5) in piston.3. When old pistons are to be used, clean the piston grooves with an acceptable piston groove cleaning tool. 4. Install the spring for the oil ring. Install the oil ring with tool (A). The gap in the ring must be approximately 180° from the oil ring spring connections.5. The two compression rings have marks "UP-1" and "UP-2". The rings must be installed with these marks toward the top of the piston with "UP-1" as the top ring. After installation of all three piston rings, put piston rings in position so gaps in rings are 120° apart. Compression rings that do not have identification can be installed either way.6. To check the clearance between the piston ring grooves and rings, see SPECIFICATIONS.7. See SPECIFICATIONS to check the clearance between the ends of the piston rings (end gap).END BY:a) install pistons