21311705 Volvo.Penta Relay

Remove Air Compressor
1. Loosen clamps (2) and remove pipe assembly (1) from the machine.
To prevent possible personal injury, release all the air from the system before any lines are disconnected.
2. Disconnect seven lines (4) from air compressor (3). 3. Remove bolts (5), the nut, air compressor (3) and the gasket from the flywheel housing.Install Air Compressor
1. Put the gasket and air compressor (1) in position on the flywheel housing, and install bolts (2) and the nut that hold it.2. Connect seven lines (3) to the air compressor. 3. Install pipe assembly (5) on the machine, and tighten clamps (4) that hold it.Disassemble Air Compressor
START BY:a. remove air compressorb. remove accessory drive1. Remove the elbows and the connectors from the air compressor. 2. Remove bolts (1) from the cylinder head. Remove cylinder head (2) and the gasket from the crankcase. 3. Remove inlet valve springs (7).4. Remove (discharge) valve seats (6) from the cylinder head. Remove valves (8) and springs (5).5. Inspect the valve seats for damage and wear. Make replacements if necessary. 6. Check valve stops (9) for wear or damage. If the valve travel exceeds 1.45 mm (.057 in.), make a replacement of the cylinder head.7. Remove bolts (3) from the adapter. Remove adapters (4) from the compressor housing. 8. Remove O-ring seal (10), the thrust washer and the bearing from the adapter with tool (A).9. Remove bolts (12) from the cover. Remove cover (11) and the gasket from the crankcase. 10. Bend down the lock on lock straps (13). Remove bolts (14) from the bearing caps.11. Put identification marks on the bearing caps for correct installation with the connecting rod. Remove the bearing caps. 12. Remove pistons (15) from the crankcase through the top of the cylinders.13. Remove crankshaft (16) from the crankcase. Remove the key from the crankshaft. 14. Remove end cover (17) from the crankcase. Remove the O-ring seal, the thrust washer and the bearing.15. Remove cover (18), the gasket and the strainer from the air inlet opening.
Be careful not to cause damage to the inlet valve seats.
16. Remove inlet valves (20) from their guides (21). Remove the inlet valve guides from around the inlet valve seats.17. Remove (unloader) spring (19), spring saddle (22) and the spring seat from the housing with needle nose pliers. 18. Remove (unloader) plunger (24) and guides (25) from the housing. Remove the guides from the plungers.19. To remove (unloader) pistons (23) from the bore, put a cover over the inlet port, then blow air pressure in the governor mounting pad (unloader) port. 20. Remove the plug and lockpin (27) that holds rod pin (26) in the piston. Remove the pin from connecting rod (28). 21. Remove the piston rings from piston (30). Remove two compression rings (29), the oil ring and the expander ring with a suitable tool.22. Remove the bearings from the connecting rod and the connecting rod cap. 23. Remove the piston pin bushing with tool (A).24. Remove the small seal rings from both ends of the housing.25. Clean all the oil passages through the housing, the crankshaft, the end cover and the adapter.Assemble Air Compressor
1. Clean and inspect all parts of the air compressor for wear or damage, and make a replacement if necessary. 2. Check (unloader) bore bushings (1) for damage and wear. If these bushings need replacement, remove the bushing by the use of a 3.18 mm (.125 in.) pipe threaded tap. Then install a 3.18 mm (.125 in.) pipe threaded rod and pull the bushing straight up and out.3. Check the cylinder bores in the crankcase housing for damage (scored or out of round). Measure the cylinder bore in several places. If the measurement difference is more than 0.03 mm (.001 in.) or taper is more than 0.05 mm (.002 in.), the cylinder bore must be made larger (rebored or honed oversize).4. Install seal rings (3) in both ends of the crankcase housing.5. Install the new (unloader) pistons in their bore.
Be careful not to cause damage to the O-ring seals or the spiral rings.
6. Put the unloader plungers in their guides. Install the plunger and guide as a unit (6) to the crankcase housing and on top of the pistons. Install the unloader spring seat in the crankcase housing.7. Put saddle (4) in position between the unloader piston guides. Install (unloader) spring (8). Make sure it makes a seat on the spring seats and on the saddle.8. Install inlet valve guides (10) on (unloader) bore bushing (2) in the crankcase housing. Put inlet valves (9) in the guides.9. Install strainer (7), the gasket and cover (5) over the air inlet port of the crankcase housing. Install the bolts that hold the cover. 10. Install bearing (11) in the cover with tooling (A). Make sure the groove in the bearing is in alignment with the oil hole in the cover. Install thrust washer (12) and O-ring seal (13).11. Put clean SAE 30 engine oil on the bearing and the seal. Install the end cover and the bolts that hold it to the crankcase housing.12. Install the crankshaft in the crankcase housing and the end cover bearing. 13. Install the bearing in the adapter with tooling (A). Install thrust washer (14) and O-ring seal (15) in the adapter.14. Put clean SAE 30 engine oil on the bearing and the O-ring seal. Install the adapter over the crankshaft and to the housing. Install the bolts that hold the adapter. Tighten the bolts to a torque of 49 to 60 N m (38 to 45 lb.ft.). 15. Install the piston rings on the piston as follows:a. Check the piston ring gaps. Check with the piston rings in the cylinder bore. The gap clearance must be 0.05 to 0.25 mm (.002 to .010 in.). b. Install expander ring (17) on the bottom groove of the piston. Install oil ring (19) over the expander ring. Expander and oil ring (19) must have a clearance of 0.03 to 0.08 mm (.001 to .003 in.) between the inside groove top