3812696 Volvo.Penta Pump

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     1U-6683     Ring Expander     1    
B     393-2568     Bearing Removal Tool     1    
443-9447 Support Plate     1    Note: Refer to Specification UENR0995 "Engine Design" for non-specified engine Torque Values.Note: The C3.3B has three different piston heights that very 0.05 mm (0.002 inch) from each. Refer to the following Table 2 to ensure that the same piston height is replaced. If the same piston height is replaced, then the same head gasket thickness can be used. If a different piston height is used, then check the piston height to determine the proper head gasket thickness. Refer to "Cylinder Head - Remove and Install" for the correct head gasket.
Table 2
Code Stamped on Standard Piston     Standard Replacement Piston     0.50 mm Oversized Piston     Code Stamped on Oversized Piston    
1J751-2111     387-9833     393-2885     1J751-2190    
1J751-2112     387-9834     393-2886     1J751-2191    
1J751-2113     387-9835     393-2887     1J751-2192    
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Illustration 1 g03696355
Inspect the connecting rod for wear and damage. If necessary, replace connecting rod (5) or replace connecting rod bushing (9) .Note: If connecting rod (5) or the bushing (9) for connecting rod pin are replaced, refer to Specifications, "Connecting Rods" for the correct procedure.
Place the piston on a suitable surface with the crown upward. Use Tooling (B) in order to install connecting rod bushing (9) into connecting rod (5) .
Illustration 2 g02723375
Check connecting rod bushing (9) . If necessary, install connecting rod bearings (6) into connecting rod (5) and connecting rod cap (8) . Inspect bolts (7) or replace with new for assembly later.
Illustration 3 g02723373
Lubricate the bore for the piston wrist pin (3) with clean engine oil.
Illustration 4 g02864817
Place piston (1) on a suitable surface with the crown downward. Position connecting rod (5) with the markings (5A) on same side as the arrow mark (5B) on top of the piston.
Install piston wrist pin (3) into piston (1) . Install retaining ring (4) .
Illustration 5 g02723365
Illustration 6 g02723368
Illustration 7 g02797867
Position the connecting rod and piston (1) into a soft jaw vise. Use Tooling (A) in order to install three rings (2) onto piston (1) .
If the original piston is assembled, follow Step 9.a through Step 9.e in order to install the piston rings.
Position the spring for the oil control ring into the oil ring groove in piston (1) . The central wire must be located inside the end of the spring.
Position the oil control ring with the word "TOP" in the upward position and use Tooling (A) to install over the piston and the spring. Refer to illustration 7.Note: Ensure that the central wire is 180 degrees from the ring gap.
Use Tooling (A) to install the intermediate compression ring into the second groove in piston (1) . The word "TOP" must be upward. The chamfer on the inner face must be downward. Refer to illustration 7.
Use Tooling (A) to install top the compression ring into the top groove in piston (1) . The manufacturing mark must be upward. Refer to illustration 7.
Position piston ring (2) gaps at 120 degrees away from each other.
Repeat Step 2 through Step 9.e for the remaining piston and connecting rod assemblies.End By: Install pistons and the connecting rods.