467365 Volvo.Penta Plug

Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-6357(1)
or
8T-3022(2) Connecting Rod Guide 1
B 235-0612 Lift Bracket 1
C 136-1452 Retaining Ring Pliers As 1
D 318-3117(3) Ring Expander Gp 1
318-4874(4) Ring Expander Gp
E 443-4072(5) Cover 1
443-4073(6) Cover 1
F - Board
51 mm by 152 mm by 1.8 m (2 inch by 6 inch by 6.0 ft) 2
G 1U-8692 Piston Pin Guide 1
H 4C-5719 Piston Ring Compressor 1
J 8T-5096
or
1U-8869 Dial Indicator 1
K 498-6540(7) Tensioner Pump Group -
498-6541(8)
L 498-6542 Tensioner Group 1
M 498-6573 Nut - Plastic(9) 4
N - 3/8 drive ratchet 1
(1) Use with V-engines
(2) Use with in-line engines
(3) 280 mm (11.0 inch) diesel
(4) 300 mm (11.8 inch) gas
(5) 3606 and 3608
(6) 3612 and 3616
(7) 115 Volt
(8) 230 Volt
(9) Part of the 498-6542 tensioner group.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g06035725Note: Ensure that there is no damage to the shank of connecting rod bolt (3) prior to the installation of heat shrink tube (10).Note: Ensure that the shanks of connecting rod bolts (3) are free of debris and oil prior to installation.Note: The connecting rod bolt (3) may be reused if bolt reuse guidelines in Reuse and salvage Guidelines, SEBF8301, "Inspection and Reuse of Critical Fasteners Used in All Engines" are met. An overloaded bolt can be detected by threading connecting rod nut (2) onto the bolt by hand. If the threads are not damaged, connecting rod nut (2) will easily reach the end of the bolt thread with light finger pressure. If connecting rod nut (2) stops before reaching the end, do not reuse the bolt.
If a new heat shrink tube needs to be installed, follow Step 1.a through Step 1.d.
Clean the shank of connecting rod bolt (3) free of debris and oil.
Slide the new heat shrink tube (10) onto connecting rod bolt (3). Install the new heat shrink tube (10) to Dimension (Y). Dimension (Y) is 1.50 mm (0.059 inch).
Use a suitable heat gun or use a suitable oven to shrink the heat shrink tube (10) onto connecting rod bolt (3). If a suitable oven is used, heat the connecting rod bolt (3) and heat shrink tube (10) at a temperature of 135° 14° C (275° 57°F) for 10 minutes.
After installation of the new heat shrink tube (10) onto connecting rod bolt (3), allow connecting rod bolt (3) to cool. Ensure that heat-shrink tube (10) does not have any bumps or wrinkles. Ensure the heat-shrink tube (10) does not move under light finger pressure.
Illustration 2 g03376355Note: Ensure that piston (4) is clean and meets reuse guidelines.
Before the piston rings are installed on the piston, check the end gap on each piston ring. Refer to Specifications, "Piston and Rings".
Do not install the piston rings without the use of the piston ring expander. Piston ring breakage and piston damage may result if the piston ring expander is not used.
Use Tooling (D) to install the piston rings on piston (4).
The piston ring gaps should be separated by 120 degrees. Install the piston rings in the following manner:
Install the piston ring expander on the piston. The ends of the oil ring spring should be installed 180 degrees from the oil ring end gap. The white portion of the oil ring spring must be visible at the ring end gap.
If installing a fourth piston ring, the third piston ring must be installed with Mark "UP-3" upward.
The second piston ring must be installed with Mark