479863 Volvo.Penta Tappet

Introduction
This instruction contains adaptability and installation information for the Remanufactured Engines listed in the chart that follows. If the engine or the block is to be used for a core credit, refer to:Reference: *PEGP7818-01 ... Core Acceptance Criteria (Engines) ... and/or*PEGP7825-01 ... Core Acceptance Criteria (Short Block)Reference Literature
Exchange of Parts
Each Remanufactured Engine is built to a reference engine arrangement, as given in the chart above.No modification or parts exchange is necessary if the replacement engine arrangement is the same as the original engine arrangement.Some modification or parts exchange may be necessary when the Remanufactured Engine reference arrangement number is different than the original engine arrangement number.Use the reference literature when necessary to exchange parts between the original and new engine. Although some of the parts on the new engine may be different from those on the original engine, an exchange may NOT be necessary, depending upon the specific application.In some installations it may be more advantageous to make minor modifications to the machine frame or engine mounting rails, rather than to exchange components between the Remanufactured Engine and the original engine.Before installation of the Remanufactured Engine, make sure the flywheel housing, flywheel and vibration damper/crankshaft pulley are compatible with your application.Each Remanufactured Engine is rated at a specific power rating at a specific rpm.The Remanufactured Engine that is to be installed will not necessarily have the same kW (Hp)/rpm rating as the original engine that it is replacing.The kW (Hp)/rpm rating setting(s) of the Remanufactured Engine can be adjusted to the same kW (Hp)/rpm rating as the original engine. Do NOT change/adjust any fuel setting(s) before referring to the:* FUEL SETTING INFORMATION LIBRARY ... and/or* FUEL SETTING AND RELATED INFORMATION microfiche.For maximum life of the Caterpillar Remanufactured Engine, the following components MUST be inspected for reusability before installation: Air CompressorThe engine oil is the source of lubrication and must be inspected for contamination as foreign material from a failure of the former engine can decrease engine life.Worn air compressors can be a source of high oil consumption by pumping oil into the engine air intake pipe, or the vehicle's air tanks. Air CleanerThe engine air inlet system should be inspected and components replaced if worn:* Install a new air filter element.* Install all hoses and clamps as necessary.* Inspect air inlet piping and connections for leaks.* Repair or replace as required. Radiator* Clean and/or flush as required.* Inspect for exterior fin damage.* Inspect for leaks.* Install new hoses and clamps. Viscous Fan Clutch (If equipped)If the engine is equipped with a viscous fan clutch:* Inspect for leaks.* Check fan speed to be sure of proper operation. Water Separator (Recommended)Some of the Remanufactured Engines that come from the factory may NOT have a factory installed water separator.However, it is a Caterpillar recommendation that a water separator be installed.Inspect the original water separator for reusability or replace as needed.If the original is used, refer to the Operation & Maintenance Manual before installation. Oil PanCompare the oil pan configuration on the Remanufactured Engine with that of the original engine.If they are different:* The oil pan from the remanufactured engine must be changed to match the original engine.* If the oil pan is changed:* The oil pump suction bell must be changed to fit the oil pan sump location.* The dipstick and guide tube may also need to be changed and/or recalibrated for a particular application. Fuel SystemCompare power ratings and rpm settings on the engine information plate of the Remanufactured Engine to the information with the same settings of the original engine.If the settings are different:* Some fuel system adjustment(s) must be made.If a part(s) change or fuel setting is required, for a specific engine application, refer to the:* Fuel Setting Information Library ... and/or* Fuel Setting and Related Information Library* Parts Book1* Service Manual1The engine arrangement number, stamped on the 9L6531 Engine Information Plate, can also be used to reference the Parts Book for the parts required within a specific engine arrangement. Whenever engines are reset to new specifications, a 4W5140 Plate stamped with the NEW specifications, MUST be installed over a portion of the original engine's 9L6531 Engine Information Plate.Refer to:* Service Magazine ... March 5, 1984* Engine News ... April 7, 1984* Truck Engine News ... April 4, 1984. FlywheelThe original engine flywheel must be removed, cleaned and inspected for reusability.If the original flywheel can not be used again, refer to the specific Parts Book to find the correct part number flywheel to use.Install the flywheel on the Remanufactured Engine and tighten the bolts to the correct torque.Refer to the Service Manual for the torque specifications.
The 0R3687 Remanufactured Engine features a 3 ring piston design, a different damper and a DIFFERENT flywheel than the original engine with the 2 ring piston design.The 0R3687 Remanufactured Engine is equipped with the new damper only. The reuse of the original flywheel, installed onto a 0R3687 Remanufactured Engine, can cause vibrational problems.While general experience says any vibration problems should be minimal, the reuse of the original should be the customers decision.Caterpillar does NOT assume any responsibility for ANY subsequent damage and/or repairs traceable to the reuse of the original flywheel or similar design flywheel installed onto a 0R3687 Remanufactured Engine.
Refer to Truck Engine News ... June 1989, for a listing of the part numbers of flywheels used with the 3 ring design piston. Governor (Accelerator) ControlRemove the governor (accelerator) control from the original and install onto the Remanufactured Engine.Refer to the Service Manual for correct adjustment.Remove any remaining componets, alternator, starter motor etc., from the original engine and inspect for reusability.The componets, if not in acceptable condition for reuse, should be reconditioned, or replaced with new or remanufactured parts.Turbocharger (Identification)
The type (early model ... later model) turbocharger MUST be identified before any turbocharger or componets are exchanged/transferred.Early Model Turbocharger
Example of early model design turbocharger. Reference (E) is the rear face of the flywheel housing.Some early model engines have a turbocharger (1) that fastens to a mounting bracket (2).The Mounting bracket is installed