20529445 Volvo.Penta Plug

Start By:a. remove oil pumpFluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Products Guide", NENG2500 for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates. 1. Check each connecting rod cap for its location on the crankshaft. Each cap (1) must have a number which is the same as the number on the connecting rod. Do not mix bearings.2. Use Tool (A) to turn the crankshaft until two of the pistons are at bottom center.3. Remove connecting rod caps (2). Remove the lower bearing from the connecting rod caps.4. Push the connecting rods away from the crankshaft and remove the upper bearings from the connecting rods.
Be careful not to damage the crankshaft journals. Do not turn the crankshaft while any of the connecting rod caps are removed.
Install the connecting rod bearings dry when the clearance checks are made. Put clean engine oil on the connecting rod bearings for final assembly.5. Install the upper half of the rod bearings in the connecting rod.6. Install the lower half of the rod bearing in the connecting rod cap. Make sure Plastigage (4) is in position on the lower bearing.The serviceman must be very careful to use Plastigage, Tool (B) correctly. The following points must be remembered:...Make sure that the backs of the bearings and the bores are clean and dry....Make sure that the bearing locking tabs are properly seated in their slots....The crankshaft must be free of oil where the Plastigage touches it....If the main bearing clearances are checked with the engine upright or on its side, the crankshaft must be supported. Use a jack under an adjacent crankshaft counterweight and hold the crankshaft against the crown of the bearing. If the crankshaft is not supported, the weight of the crankshaft will cause incorrect readings....Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing....Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed.... Do not turn the crankshaft with the Plastigage installed....Carefully remove the cap but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements....Remove the Plastigage before reinstalling the cap....When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004 in) the readings may be low by 0.013 to 0.025 mm (.0005 to .0010 in). Out-of-round journals can give faulty readings. Also, journal taper may be indicated when one end of the Plastigage is wider that the other.For complete details concerning measuring bearing clearances, see Engine Bearings & Crankshafts SEBD0531. Be sure tab (3) on the back of the bearings fits in the groove of the caps and connecting rods. When connecting rod caps are installed, make sure the number on the side of the cap is next to, and respective with, the number on the side of the connecting rod. 7. Put clean engine oil on bolt threads (5). Put caps (2) in position on the connecting rods and install the nuts. Tighten the nuts with the procedure that follows: a. Tighten each nut (6) to a torque of 81 8 N m (60 6 lb ft). b. Put a mark across the nuts and bolts. Tighten the nuts 120 degrees more.
Do not use an impact wrench to tighten the nuts the additional 120 degrees.
8. Remove the cap and measure the Plastigage. The rod bearing clearance for new bearings must be 0.071 to 0.168 mm (.0028 to .0066 in). The maximum clearance for used bearings is 0.25 mm (.010 in).9. Put bearing cap (2) in position and tighten the bolts as in Step 7.10. Do steps 1 through 9 for the other connecting rod bearings.End By:a. install oil pump