838367 Volvo.Penta Push rod

Table 1
Required Tools
Tool Part Number Part Description Qty.
A 5R-7425 Barring Gp 1
B 1P-1861 Retaining Ring Pliers 1
C 271-0498 Expander Ring 1
H 485-8003 Tool As 1
J 7X-7699 Grease -
K 471-6593 Tool As
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01004841
Illustration 2 g06156652Note: Ring grooves are to be 100% lubricated with engine oil prior to the assembly of the rings.
Use Tooling (C) to install the piston rings (6) onto the piston7.Note: Assemble top ring with side marked "UP-1" toward the top of the piston.Note: Assemble the middle ring with the side marked "Up-2" toward the top of the piston.Note: Oil ring spring ends to be assembled 180° from ring end gap.
After rings have been assembles, rotate rings so the end gaps are 120° apart. Oil ring end gap must be in pin bore plane.
Pin mating surface: from pin (5) to bore and pin (5) to bearing must be 100% lubricated with engine oil prior to assembly.
Position connecting rod (8) in piston (7) and install piston pin (5).
Illustration 3 g06156977
Use Tooling (B) to install the retaining rings (4) in the position shown to hold the piston pin (5).
Install the upper portion of the connecting rod bearing in the connecting rod (8). Ensure that the tab on the back of the bearing is in the bearing tab groove in the connecting rod (8).
Illustration 4 g06157138
Install Tooling (K) on cuffed liners.
Coat the piston rings, the cylinder liner bore, and the upper portion of the connecting rod bearing with clean engine oil.
Illustration 5 g01004842
Use Tooling (H) to compress piston rings.
Illustration 6 g06157160
Improper installation of the piston and connecting rod assembly will result in severe damage to the engine.
Make sure that the side of the connecting rod bore with the chamfer is oriented next to the surface of the crankshaft thrust plate. The square side of the connecting rod bore must be next to the other connecting rod that is on the same crankshaft journal.
Install the piston and connecting rod assembly into the cylinder liner. Ensure that the side of the connecting rod bore with the chamfer is oriented next to the crankshaft thrust plate. The square side of the connecting rod bore must be next to the other connecting rod that is on the same crankshaft journal.
Illustration 7 g06156532
Install the lower half of the connecting rod bearing in connecting rod cap (2). Ensure that the tab on the back of the bearing is in the bearing tab groove on the connecting rod cap (2). Coat the bearing with clean engine oil.
Apply Tooling (J) to the bolt threads and to all bearing surfaces.
Position the connecting rod cap (2) on the connecting rod and install bolts (1).
Illustration 8 g06157182
Tighten bolts (1) and (2) to a torque of 90 5 N m (66 4 lb ft).
Tighten bolts (3) and (4) to a torque of 90 5 N m (66 4 lb ft).
Retighten bolts (3) and (4) to a torque of 90 5 N m (66 4 lb ft).
Tighten each bolt an additional 90° 5°.End By:
Install the piston cooling jets.
Install the cylinder head.