858040 Volvo.Penta Instrument panel

1. Make an adjustment of the legs on tool (A) for the length of the cylinder liner. Be careful not to damage the cooling tube at the bottom of the cylinder liner.2. Turn the nut on tool (A) until cylinder liner (1) is free of the cylinder block. 3. Remove seals (3) and filler band (2) from the cylinder liner.Install Cylinder Liners
1. Install the gasket and spacer plate.2. Clean the cylinder liners and liner bores in the cylinder block. 3. Install cylinder liners (1) in the cylinder block without seals or bands. 4. Check the cylinder liner projection as follows:a. Install four bolts (4) and eight seals (washers) from tooling (A) around each cylinder liner as shown. Tighten the bolts evenly, in four steps: 14 N m (10 lb.ft.), 35 N m (25 lb.ft.), 70 N m (52 lb.ft.) and then to 95 N m (70 lb.ft.). To prevent movement of the bolts and seals as each liner is checked, install two bolts with seals on each side of each cylinder liner, along the complete length of the top plate.b. Install plate (3), crossbar (6) and plates (5) from tooling (A) and bolts (2) and the washers from tooling (C). Be sure the crossbar is in position at the center of the liner and the liner surface is clean. Tighten the bolts evenly, in four steps: 7 N m (5 lb.ft.), 20 N m (15 lb.ft.), 35 N m (25 lb.ft.) and then to 70 N m (52 lb.ft.).c. Check the distance from the bottom edge of crossbar (6) to the top edge of the spacer plate. The distance on each end of the crossbar must be the same.d. Check the liner projection with tool (B) at four locations around the liner flange. Liner projection must be 0.025 to 0.152 mm (.0009 to .0059 in.). The difference between the four measurements on the same liner must not be more than 0.05 mm (.002 in.). The difference between average liner projection for liners next to each other must not be more than 0.05 mm (.002 in.). The maximum difference in the average projection of the cylinder liners under each cylinder head must not be more than 0.10 mm (.004 in.). If the liner projection changes too much from point to point around the liner, turn the liner to a new position in the bore. If the projection measurements are still not within specifications, move the liner to a different bore in the cylinder block and check the projection again. 5. If the liner projection is not 0.025 to 0.152 mm (.0009 to .0059 in.), check the thickness of the following parts: spacer plate 8.59 0.03 mm (.338 .001 in.), spacer plate gasket 0.20 0.03 mm (.008 .001 in.) and cylinder liner flange (7) 8.890 0.020 mm (.3500 .0008 in.).6. The cylinder liner projection can be changed if a counterbore is made in the block to a minimum depth of 0.76 mm (.030 in.) and to a maximum of 1.14 mm (.045 in.). Shims are available to adjust the liner to the correct projection. See Special Instruction Form No. FM055228 for the procedure to use the 8S3140 Cylinder Block Counterboring Tool Arrangement. Be sure that the 0.76 mm (.030 in.) shim is directly under the cylinder liner flange if more than one shim is used. Put 7M7260 Liquid Gasket on the top shim and on the bottom of the bottom shim before installation.7. Put a mark on the liner and the block so the liner can be installed in the same position from which it was removed.8. Remove tooling (A), (B) and the liner. 9. Put liquid soap on O-ring seals (8), the grooves of the liner and the bore of the cylinder block. Install O-ring seals (8) on the cylinder liner.
The Cylinder liner must be installed in the block immediately after the filler band is installed on the liner. The filler band gets larger after it has been put in oil and can be damaged when installed if there is a time delay in installation.
10. Put (dip) filler band (9) completely in clean SAE 30 oil and install immediately. Install the filler band on the cylinder liner. 11. Install the liner immediately after the filler band is installed. Make sure the mark on the liner is in alignment with the mark on the block. Use tooling (C) to push the liner into position.12. Install the remainder of the cylinder liners.END BY:a. install pistonsb. install spacer plates