382504 Volvo.Penta Gasket

Table 1
Required Tools
Tool Part Number Part Description Qty
A 5R-7425 Barring Gp(1) 1
B 1P-1861 Retaining Ring Pliers 1
C 271-0498 Expander Ring 1
D 1U-7616 Piston Ring Compressor Gp 1
E 334-0519 Grease -
(1) The 9S-9082 Engine Turning Tool is alternative tooling.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g02042299
Use Tooling (C) to install piston rings (7) onto piston (3).
For the oil control ring, ensure that the ends of the spring are 180 degrees from the ring gap. The white portion of the spring must be visible at the ring gap.
Install the intermediate ring with the side marked "UP-2" toward the top of the piston.
Install the top ring with the side marked "UP-1" toward the top of the piston.
After the rings are installed, rotate the rings so that the gaps are spread apart by 120 degrees. Orient the oil control ring gap toward the bore for the piston pin.
Illustration 2 g02042296
If necessary, place the piston crown into the piston skirt.
Use clean engine oil to coat the bore of piston (3), piston pin (6), and the piston pin bearing in connecting rod (5). Position connecting rod (5) inside piston (3). Insert piston pin (6) through piston (3) and the bearing.
Use Tooling (B) to install retaining rings (4). Orient the retaining ring gaps toward the top of piston (3).
Install the upper half of the connecting rod bearing in connecting rod (5). Ensure that the tab on the back of the bearing is in the bearing tab groove in connecting rod (5).
Coat the piston rings, the cylinder liner, and the upper half of the connecting rod bearing with clean engine oil.
Illustration 3 g02042533
Illustration 4 g00613051
Chamfer on one side of the connecting rod bore
Use Tooling (D) to compress the piston rings.
Install the piston and connecting rod assembly into the cylinder liner. Ensure that the side of the connecting rod bore with the chamfer is oriented next to the surface of the crankshaft thrust plate. The square side of the connecting rod bore must be next to the other connecting rod that is on the same crankshaft journal.
Illustration 5 g02042295
Install the lower half of the connecting rod bearing in connecting rod cap (2). Ensure that the tab on the back of the bearing is in the bearing tab groove on connecting rod cap (2). Coat the bearing with clean engine oil.
Apply Tooling (E) to the threads of bolts (1) and to all of the surfaces of bolts (1) that contact connecting rod cap (2).
Position connecting rod cap (2) on the connecting rod and install bolts (1).
Illustration 6 g02043173
(X) Side of the connecting rod with the chamfer
(Y) Location pin
Tighten Bolts (A) and (B) to a torque of 90 5 N m (65 4 lb ft).
Tighten Bolts (C) and (D) to a torque of 90 5 N m (65 4 lb ft).
Tighten Bolts (C) and (D) again to a torque of 90 5 N m (65 4 lb ft).
Tighten all of the bolts for an additional 90 5 degrees (1/4 turn).
Check the side clearance that is between two of the connecting rods that are on the same journal. The clearance must be 0.850 0.332 mm (0.0335 0.0130 inch). End By:
Install the piston cooling jets.
Install the spacer plates.