3851976 Volvo.Penta Housing

Table 1
Required Tools
Tool Part Number Part Description Qty
A 207-5034(1) Stud Tensioner Tool Gp 1
301-5215(2) Stud Tensioner Tool Gp 1
B 8T-0820 Hydraulic Pressure Gauge 1
3S-6224(3) Electric Hydraulic Pump 1
8S-8033(3) Electric Hydraulic Pump 1
9U-6600(3) Hand Hydraulic Pump 1
8T-3035 Hydraulic Line 1
C 126-6918(4)
or
126-6919(5) Lifting Bracket 1
126-6920 Handle Rod 1
5D-1972 Bolt 2
D 229-3639 Overhaul Protection Gp 1
F 183-3424 Water and Temperature Resistant Grease 1
(1) Operating pressure is 40000 1520 kPa (5800 220 psi).
(2) Operating pressure is 125000 4920 kPa (18130 715 psi).
(3) There are three pumps that are listed in the tool chart. Any one of the pumps may be used for this procedure.
(4) Use with V-engines
(5) Use with In-line engines
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Tooling (D) provides all the protective covers and plugs for one cylinder. Use these protective covers in order to maximize the protection during these procedures.
Thoroughly clean the sealing surfaces on top of the cylinder block assembly.
Remove all debris from the inside of the cylinder liner and top of the piston. Apply clean engine oil to the inside of the cylinder liner.
Earlier engines may have RTV coating on the cylinder head studs. Remove all debris from the holes in the cylinder block. Thoroughly clean the cylinder head studs and the top surface of the cylinder block. Paint the cylinder head studs if the cylinder head studs were cleaned to the bare metal.
If the cylinder head studs were removed, use the following procedure to install the cylinder head studs:
Before installing the cylinder head studs, coat the lower half of the cylinder head studs with Tooling (F). Apply an extra bead of grease around the cylinder head studs at the base of the cylinder head studs on the face of the block. This will help ensure that the counterbore in the top of the block is full of grease.
Thoroughly clean the top of the cylinder block.
Install the cylinder head studs in the block and tighten to a torque of 100 20 N m (75 15 lb ft).
Coat the entire length of the cylinder head studs with Tooling (F) after the cylinder head studs are installed in the cylinder block.
Always install the seal plates after the cylinder liners are installed. Aluminum debris shaved from the plates by the cylinder liners will prevent the cylinder liners from sealing if the plates are installed first.
Note: Steps 6 through 10 are for engines that are equipped with flange cooled cylinder liners.
Illustration 1 g01337529
Flange Cooled Cylinder Liners
Be sure that the O-ring seals and plugs (17) are installed at four locations around each flange cooled cylinder liner. Note: Later cylinder blocks do not have the plugs that are shown in the photo.
Install O-ring seals (16) on cylinder liner (14). Apply clean petroleum jelly to the O-ring seals.
Illustration 2 g01337530
The photo shows the bottom side of seal plate (15).
Put a new O-ring seal at Locations (20) and (19) in seal plate (15). Put new O-ring seals at Locations (21) and (18) in seal plate (15). Apply petroleum jelly in the bore in the seal plate for the cylinder liner.
Illustration 3 g01337531
Turn seal plate (15) so that the top side is facing upward. Place the seal plate over the cylinder head studs and then place the seal plate onto the cylinder block.
Put a new O-ring seal at Locations (20) and (19) in seal plate (15). Put new O-ring seals at Locations (21) and (18) in seal plate (15).
Illustration 4 g01337525
Cuffed liner