802900 Volvo.Penta Fitting

Table 1
Required Tools
Tool Part Number Part Description Qty
A 456-6500 Engine Rollover Stand 1
284-8777 Plate (Rear) 1
284-8766 Plate (Front) 1
B 253-3272 Cylinder 2
C 178-9312 Hose As 2
D 253-3276 Distribution Coupler 1
E(1)(2) 227-6724 Electric Hydraulic Pump Gp (120 V) 1
227-8834 Electric Hydraulic Pump Gp (240 V) 1
191-5347 Hydraulic Pump Gp 1
156-7167 Manual Hydraulic Pump 1
F 284-5266 Spanner Wrench As 1
G - Bel-Ray Molylube 67700(3) -
(1) Use any of the pumps that are listed in Tooling (D) for this procedure.
(2) The latest pumps and hoses require 151685 kPa (22000 psi) capacity.
(3) Refer to the following link to order mollylube specified above - www.belray.com
Illustration 1 g01224414
Lubricate main bearing studs (17) with clean engine oil. Install main bearing stud (17). Use Tooling (F) and a suitable torque wrench to tighten main bearing stud (17). Tighten main bearing stud (17) to a torque of 100 20 N m (74 15 lb ft).
Illustration 2 g01224408
Install thrust bearing (15) into the rear of cylinder block (14). Lightly lubricate upper main bearings (16) and the upper connecting rod bearings with clean engine oil. Install upper main bearings (16) into cylinder block (14).
Illustration 3 g01224401
Attach a suitable lifting device onto crankshaft (12). The weight of crankshaft (12) is approximately 748 kg (1650 lb). Install crankshaft (12).
Use Tooling (A) to rotate the engine slightly above the horizontal position.
Illustration 4 g01432463Note: Match the tabs on the ODD and EVEN connecting rod caps with the connecting rod.
Position pistons (10) toward crankshaft (12). Lubricate the bearings for rod caps (9) with clean engine oil. Install rod caps (9). Apply Tooling (G) under the bolt heads (8) and to the bolt threads (3). Install bolts (8) finger tight.
Illustration 5 g03766281
The arrow represents the front of the engine block
Bolt numbering for 316-0062 Connecting Rod, 316-0063 Connecting Rod, 434-0480 Connecting Rod, and 434-0481 Connecting Rod. Bolt (1) is always identified as the center bolt on the bearing tab side of the connecting rod.
(A) Bearing tab side
(X) Odd numbered connecting rod
(Y) Even numbered connecting rodNote: Identify the connecting rod part number to determine which of the following torque procedures to follow.
Use the following procedure to tighten the connecting rod bolts for Type 1 connecting rods:
Table 2
Assembly Specification for Type 1 Connecting Rods with 290-2541 Bolts
Item Qty Part Specification Description
8 6 290-2541 Bolts Use the following procedure to tighten the bolts of the connecting rod:
Note : Apply Bel-Ray Molylube 67700 to the threads and middle rings of bolt (2) and the contact surface under the bolt head. Refer to the following link for ordering purpose.
www.belray.com
1. Install the spacers (2) and the bolts (1). Hand tighten the bolts.
Note : Bolt 1 is identified as the middle bolt on the tab side of the bearing on the connecting rod. Tighten this bolt first to seat the bearing into the bore.
2. Tighten bolt 1 and bolt 2 to 105 5 N m (77 4 lb ft).
3. Tighten bolt 3 and bolt 4 to 105 5 N m (77 4 lb ft).
4. Tighten bolt 5 and bolt 6 to 105 5 N m (77 4 lb ft).
5. Again tighten bolt 1 and bolt 2 to