3964833 Volvo.Penta Gasket

Basic Block
Cylinder Block Honing
The following preliminary check is essential to determine if honing is necessary, and if so, the size to hone.Measure all cylinder bores during disassembly using the 1P3537 Bore Gauging Group. This Group includes a 1P3535 Dial Bore Gauge Group and a 1P3536 Size Setting Fixture Group. The bore gauging group provides more accurate measurement than other methods, such as inside micrometers. When setting the gauge, always be sure the gauge pin has sufficient travel to measure the points of maximum wear in the bore. In a cylinder bore, maximum wear is usually across the diameter perpendicular to the crankshaft centerline, either at the top or bottom of ring travel. Normal wear usually will not exceed 0.51 mm (.020 in); however, if bore wear is greater than 0.51 mm (.020 in), hone the block 1.02 mm (.040 in) oversize. The fact that the block can be honed both 0.51 mm (.020 in) and 1.02 mm (.040 in) oversize will allow a block to be reconditioned twice under normal wear conditions. The standard bore size is 114.300 to 114.338 mm (4.5000 to 4.5015 in).
1P3537 Bore Gauging GroupWhen reconditioning an engine, the bore size is the determining factor as to the necessity of honing the bores. If bores are worn 0.15 mm (.006 in) more than the standard size, the block should be honed. However, additional service may be obtained without honing if wear does not exceed the maximum wear limit of 0.216 mm (.0085 in).Before honing, inspect the bottom of each cylinder bore adjacent to the main bearing saddle or web. Some of the saddles may overlap the edge of cylinder bores enough to interfere with honing. Where overlap exists, machine a relief in the saddle to provide clearance for the honing tool. The radius of the relief must be concentric with the cylinder bore and 0.76 0.13 mm (.030 .005 in) larger than the bore radius. The relief extends 15.7 mm (.62 in) beyond the bottom of the bore, as shown. This provides adequate clearance for honing.
Relief In Saddles And Chamfer After HoningWhen honing, check bore size at several locations in the length of the bore and around the circumference. Specifically measure at points perpendicular to the crankshaft centerline at locations 6.4 mm (.25 in) from each end and at center of bore. These three specific locations are primary gauge points during and after honing.
Primary Gauging PointsWhen honing cylinder blocks, maintain the specific dimensional surface finish and cross hatch tolerances to obtain satisfactory oil control. The tolerances specified are virtually the same as those used for original bore finish at the factory, and can be obtained with an automatic honing machine such as the Sunnen CK-10. This machine has been evaluated and found to give satisfactory results.The Sunnen CK-10 machine is available from Sunnen Products Company, 7910 Manchester Avenue, St. Louis, Missouri, 63143.Due to the cost of suitable honing equipment, it may be more expedient to have the honing done by a shop equipped with a Sunnen CK-10 or equivalent.Transit Preparation
The following Steps can prevent damage to the block in transit to a shop.1. Completely disassemble, but do not clean block. The residual oil on the surface will prevent rust.2. Enclose the block in an industrial plastic bag and position it with the oil pan surface on a suitable wood pallet or equivalent. Dimensions of a suitable wood pallet are shown.
Transporting Pallet3. Cover the block with 12.7 mm (1/2 in) thick plywood or equivalent, and band block to the pallet.4. Follow similar instructions when block is returned. To prevent rust, the block should not be cleaned after honing; the film of honing oil provides ample protection from rusting. If blocks are stored for any length of time, clean and anti-rust after honing.Cleaning Procedure
After honing is completed, and before assembling the engine, the cylinder block must be cleaned and prepared according to the following instructions.1. If not previously removed, the camshaft bearings must be removed to permit thorough cleaning of the oil passages. To remove the bearings, see the topic Camshaft Bearings Removal And Installation.2. Use 1P3565 Chamfering Group, remove the sharp corner at the bottom of the cylinder bores as shown. This is essential to prevent scuffing the piston skirts. This chamfer should be approximately 10° × 2.3 mm (10° × .09 in).
Chamfering Bore
Avoid damage to the cylinder bore surface or any other parts.
3. Use the 1P5580 Brush Group and a strong detergent and water solution to clean the following areas of the block.A. Main oil gallery and supply passage. Use the 1P5572 or 1P5573 Brush and stroke several times while rotating the brush.B. Camshaft bearing oil passages. Use the 1P5571 Brush and stroke several times while rotating the brush.C. Cylinder bores. Use the 1P5574 Brush and stroke each bore for one minute while rotating the brush at 1000 rpm.
Incomplete cleaning will result in piston seizure or rapid wear of cylinder bores, pistons and rings. Only thorough rotary brushing with a strong detergent and water solution satisfactorily removes abrasive particles.
4. To clean the piston cooling jets, use a #50 drill or a length of 1.78 mm (.070 in) wire and push through the jet. Be sure the groove in the main bearing bores and the counterbores for piston cooling jets are clean and free of debris.5. Thoroughly clean the cylinder block in an agitator-type cleaning tank. This type of cleaning should follow the brushing of the cylinder bores but is not sufficient by itself for cleaning.6. Coat all machined surfaces immediately after cleaning with engine oil (SAE 30). Keep the block covered to exclude dirt until assembled.
1P5580 Brush GroupRemove and Install Piston Cooling Jets
Use a 3/16 in diameter punch approximately 305 mm (12 in) long to remove the piston cooling jets. Put the punch in the engine cylinder bore and drive the piston cooling jet into the main bearing bore.Use a FT1542 Driver to install the piston cooling jets in the main bearing bores. After installation check the orifice size in the piston cooling