991202 Volvo.Penta V-ribbed belt

Remove And Install Air Compressor
1. Drain the cooling system. The capacity of the cooling system is 106 liter (28 gal.). 2. Remove air compressor coolant outlet tube (2).3. Disconnect lubrication supply tube (3) at the governor.
To prevent personal injury, release the pressure from the air reservoir before any air lines are disconnected.
4. Disconnect air compressor governor sensing hose (4) at the governor.5. Disconnect pressure air hose (5) at the air compressor.6. Disconnect air compressor air inlet tube (6) at the air compressor.7. Disconnect air compressor coolant inlet tube (7) at the air compressor.8. Fasten a nylon strap and hoist to the air compressor. The weight of the air compressor is 23 kg (51 lb.).9. Remove three nuts (1) and the washers that hold the air compressor and adapter to the flywheel housing. 10. Disconnect the clip for tube (3) at the air compressor.11. Move air compressor (8), adapter (9) and tube (10) away from the flywheel housing.12. Cover the opening in the flywheel housing for the air compressor.13. Install protective covers in the coolant, air and oil openings. The following steps are for installation of the air compressor.14. Install a new O-ring seal on adapter (9), and put clean engine oil on it.15. Install a new O-ring seal on tube (10), and put clean engine oil on it.16. Remove the protective covers and place air compressor (8) and adapter (9) on the studs.17. Install three nuts (1) and the washers to hold the air compressor.18. Connect all hoses and tubes to the air compressor in their correct locations.19. Fill the cooling system with coolant. See the Maintenance Guide.Remove Accessory Drive (Air Compressor Drive Group)
START BY:a. remove air compressor 1. Remove nut (4) from the compressor drive shaft with tool (A). Remove spacer (3).2. Remove O-ring seal (2) from adapter (1). 3. Remove drive gear (5) from the compressor drive shaft with tool (B). Remove the key from the shaft.4. Remove the adapter and gasket (6).Install Accessory Drive (Air Compressor Drive Group)
1. Install the key on air compressor drive shaft (1).2. Install gasket (5) and adapter (6) on the air compressor.3. Put the groove in the drive gear in alignment with the key in the drive shaft. Install gear (2) on the shaft. 4. Install spacer (3) and nut (4) on the drive shaft. Tighten the nut with tool (A).5. Install O-ring seal (7) on the adapter.END BY:a. install air compressorDisassemble Air Compressor
START BY:a. remove air compressorb. remove accessory drive (air compressor drive group)1. Remove the water line elbow, the air line elbows and oil (drain) tube 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 from damage and wear. Make replacements if necessary. 6. Remove valve stops (9) as follows:a. Put the machined surface of the cylinder head down on an arbor press.b. Gradually push the stops from the top of the cylinder head and out of the bottom.c. Be sure there is enough clearance for the stops between the press and the bottom of the cylinder head.d. Inspect the stop bore in the cylinder head. Make a replacement of the head body if the bore is damaged. Remove the valve stops only if there is a wear and damage, also if the valve movement (travel) exceeds 1.45 mm (.057 in.).7. Remove bolts (3) from the adapter. Remove adapters (4) from the compressor housing. See illustration A17939P1. 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. 16. Remove inlet valves (20) from their guides (21). Remove the inlet valve guides from around the inlet valve seats.
Do not damage 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 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 tool (B).22. Remove the bearings from the connecting rod and the connecting rod cap. 23. Remove the piston pin bushing with tool (C).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. 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.2. Check the cylinder bores in the crankcase housing for damages (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 (rebores or honed oversize). See Specifications.3.