469867 Volvo.Penta Reduction valve

Table 1
Required Tools
Tool Part Number Part Description Qty
A 279-3473 Engine Turning Tool 1
329-3831(1) Air Power Turning Tool 1
B 274-5875(2) Guide 2
418-1340(3) Guide 2
339-6503 Bolt 2
C 369-4008 Piston Support 1
D 222-3117 Brake Cleaner 1
E - Loctite Moly Paste 1LB 1
(1) Optional
(2) Use for engine serial numbers 1-999 (type 1)
(3) Use for engine serial numbers 1000-99999 (type 2)Start By:
Remove the electronic unit injector.
Remove the fuel pump.
Remove the fuel filter housing.
Remove the engine oil cooler.
Remove the engine oil pump.
Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change" for the correct draining and filling procedure.
Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedure.
If necessary, remove components for access to the side covers. Remove the panel, the starting motor, and the alternator.
Illustration 1 g03347966
Remove bolts (1). Remove side cover (2).
Use Tooling (A) to turn the flywheel in order to access the connecting rod cap that will be removed.
Illustration 2 g01431477Note: Inspect and carefully handle the fractured connecting rod and the connecting rod cap for the proper identification mark. The connecting rod and the connecting rod cap should have an etched number on the side. Clean with Tooling (D) if the etching is hard to view. The number should match the cylinder number. Mark the connecting rod and the connecting rod cap, if necessary. Improper handling of the fractured connecting rods and the connecting rod caps can cause misalignment during assembly. The connecting rod caps should be placed on the side in order to prevent damage.
Remove bolts (3) and the spacer. Remove connecting rod caps (4).
Illustration 3 g02076133Note: Notice the location of the tabs when the connecting rod bearings are removed from the ODD and EVEN connecting rod caps.
Remove the lower half of connecting rod bearing (5) from connecting rod cap (4).
Illustration 4 g02049074
If necessary, rotate the crankshaft in order to install Tooling (B).
Illustration 5 g02049093
Install Tooling (C) in order to hold the piston in place.
Use the adjusting nut to raise the piston until the connecting rod is above the crankshaft journal. Remove Tooling (B) that is not against the crankshaft journal. Remove the upper half of the connecting rod bearing.
Push the connecting rod into position and remove the rest of Tooling (B). The connecting rod should swing over the crankshaft journal. Check in order to avoid contact between the connecting rod and the connecting rod journal. Installation Procedure
Clean the connecting rod cap and the connecting rod bearing bore with Tooling (D) and clean lint free rag. Inspect both the connecting rod cap and the connecting rod bearing bore. Check for carbon on the connecting rod cap and the connecting rod bearing bore.
Inspect the fractured joints and remove any loose material. Clean the face with a clean paint brush to remove loose material on the fractured areas.
Check the clearance of the bearings. Refer to Disassembly and Assembly, "Bearing Clearance - Check" for the correct procedure.
Use Tooling (D) and a lint free rag to clean the new bearing. Apply a light film of clean oil to back of bearing surface and a generous amount of oil on the front of each bearing
Install the upper half of the connecting rod bearing in the connecting rod. Inspect in order to ensure that the tab on the back of the bearing is in the bearing tab groove on the connecting rod.
Inspect the connecting rod bearing and the crankshaft journal for seating, alignment, and cleanliness. Apply clean engine oil.
Push the connecting rod into position over the connecting rod journal and install Tooling (B).
Position the connecting rod over the crankshaft. Use Tooling (C) to lower the piston on the crankshaft journal.
Illustration 6 g02049074
Remove Tooling (B).