873594 Volvo.Penta Instrument panel

Do not disconnect any air lines until the air pressure is zero.
1. Open the bleed valves to release the air pressure in the air tank. 2. Remove water inlet line (1), air inlet line (3) and the air outlet line.3. Remove water outlet line (6) and oil inlet line (5).4. Disconnect the pressure control line from the air compressor.5. Fasten a hoist to air compressor (2) and remove bolts (4) that hold it to the timing gear plate. Remove the air compressor.Install Air Compressor
1. Fasten a hoist to air compressor (2) and put it in position on the timing gear plate. Install the bolts (4) that hold it.2. Connect oil supply line (5) to the air compressor.3. Connect air inlet line (3), the air outlet line and pressure control line to the air compressor.4. Connect water inlet line (1) and water outlet line (6) to the compressor.end by:a) install engine oil cooler.Disassemble Air Compressor
start by:a) remove air compressor 1. Remove two bolts (2) and nuts to remove air compressor governor (1) from bracket (3). Remove bracket (3) from air compressor. The air compressor governor can be removed from air compressor while air compressor is on the machine. 2. Remove bubber boot from bottom of governor. Remove spring assembly (5) and sleeve assembly (4) from governor housing. 3. Disassemble spring assembly. Remove adjustment nut (6), washer (9), retainer (7), spring (10), grommets (11), spacer (8) and bolt (12). 4. Disassemble sleeve assembly. Remove valve (13) and spring (16). Remove O-ring seals (14) from sleeve. Remove spring assembly (15). 5. Remove bolts (18). Remove compressor cylinder head (17). 6. Remove two small springs (19) from cylinder head. Remove two plugs (22) from cylinder head and remove two valves (21) and two large springs (20). 7. Remove two spring seats (24). Push up on spring (26) and remove it from the cylinder block housing. Remove saddle (25). Pull piston assemblies (23) up through cylinder block housing. Put identification on the connecting rods and the caps as to their location in the cylinder block. 8. Remove cover from bottom cylinder block housing. Remove bolts (28) and locks then remove connecting rod caps (27). Push the two pistons through the top of the cylinder block. 9. Disassemble the pistons. Remove rings (29) from piston (30). Remove lock (33), then remove pin (32) from piston. Remove connecting rod (31). Remove two bearings (35), one from connecting rod and one from the connecting rod cap. Remove bearing (34) from connecting rod. 10. Remove bolts (36) and pull crankshaft cover (37). The crankshaft will come out with the cover. Make a separation between the cover and crankshaft. Remove the washer from the cylinder block. Remove O-ring seal from crankshaft cover. Remove the bearing from crankshaft cover. 11. Remove bushing from the crankcase with tooling (A).Assemble Air Compressor
1. Install bushing (1) in the crankcase with tooling (F) until it is even with the machined surface in the crankcase. 2. Install the bearing in the crankshaft cover assembly with tooling (A). Install the bearing until it makes contact with the surface inside the cover assembly. 3. Install piston rings (2) with tool (C). The rings must be installed in the correct position in the piston. The width of the rings are their identification as to their location in the piston. 4. Check the groove clearance of the piston rings. The clearance for the wide rings must be .0035 to .0055 in. (.0089 to .0140 mm). The clearance for the narrow rings must be .002 to .004 in. (0.05 to 0.10 mm). The ring gap clearance is checked with the ring in the cylinder bore. The ring gap clearance must be .005 to .015 in. (0.13 to 0.38 mm). 5. Make an alignment of the oil hole in the bushing with the oil hole in connecting rod. Install the bushing with tooling (B). New bushings must be reamed or honed until there is a clearance of .0001 to .0006 in. (0.003 to 0.015 mm) between the bushing and the piston pin. 6. Install the connecting rods (6) in the pistons. Install pin (3). Install lockpin (4). Install bearing (5) for the connecting rod and one for the connecting rod cap, with the top of the bearing in the groove. The bearings must be installed only for the respective rods and caps. 7. Put clean SAE 30 engine oil on the piston rings and connecting rod bearings. Turn the crankshaft so one of the connecting rod journals is in the "DOWN" position. Install tool (E) over the piston to put the piston rings under compression. Install piston assembly in cylinder bore. Make sure the connecting rod is over the crankshaft journal. 8. Check the clearance between the connecting rod bearing and crankshaft journals with tool (D). Put PLASTIGAGE (D) on bearing. Install the bearing caps (7) to the respective connecting rod. Tighten the bolts to a torque of 100 to 115 lb. in. (11.3 to 13.0 N m). 9. Remove the bearing caps (7) and measure the Plastigage. The clearance must be between .0003 to .0021 in. (0.008 to 0.053 mm). 10. Put clean SAE 30 engine oil on the bearing caps and the bolts. Install the bearing caps, bolts (8) and locks (9). Tighten the bolts to a torque of 100 to 115 lb. in. (11.3 to 13.0 N m). Bend the locks up against the bolts.11. Do Steps 8 through 10 for the other piston rod assembly. 12. Install the gasket and cover (10) on the bottom of the crankcase. Install the bolts (11) that hold cover (11). 13. Install piston assemblies (13) into cylinder housing. Install saddle (12), spring (14) and seat. Install two inserts (15) and two seats (16) into cylinder housing. 14. Install two large springs (19) into cylinder head (17), two valves (20) and two plugs (21). Put the two small springs (18) on the two seats (16) that were installed in the cylinder housing. Install cylinder head (17) on cylinder housing with the