3801205 Volvo.Penta Aquamatic drive, exc

Table 1
Required Tools
Tool Part Number Part Description Qty
A 439-3940 Link Bracket 2
D 8T-5096 Dial Indicator 1
E 8T-3052 Degree Wheel 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01018035
Install dowel (7) in the crankshaft.Protrusion of dowel (7) from the crankshaft face ... 6.4 mm (0.25 inch)
Install dowel (8) in the crankshaft.Protrusion of dowel (8) from the crankshaft ... 4.1 0.5 mm (0.16 0.02 inch)Note: Do not use a torch to heat the crankshaft gear. Overheating of the crankshaft gear will cause premature failure.
Raise the temperature of crankshaft gear (6) to a maximum temperature of 233° C (451° F). Install crankshaft gear (6) on the crankshaft with the keyway in alignment with dowel (8). The Timing Mark "V" of the gear should face away from crankshaft (5). If necessary, use a suitable brass drift and a suitable hammer to seat the crankshaft gear against the shoulder of the crankshaft.
Clean the cylinder block and the main bearing caps thoroughly.
Illustration 2 g01048335Note: Install the main bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check". Apply clean engine oil on the face of the main bearings for final assembly.
Install the upper halves of main bearings (9) in the cylinder block.Note: Ensure that the main bearings are installed so that the bearing tabs fit into the notch in the cylinder block. The upper halves of the main bearings have the oil groove and the oil hole.
Install Tooling (A) and a suitable lifting device on crankshaft (5). The weight of crankshaft (5) is approximately 177 kg (390 lb).
Install crankshaft (5) with the Timing Mark "V" on the crankshaft gear in alignment with the Timing Mark "V" on the cluster gear.
Illustration 3 g01048338
Install thrust plates (10) on each side of the No. 4 main bearing.Note: Install the thrust plates with the words "Block Side" toward the cylinder block.
Install the lower halves of the crankshaft main bearings in the main bearing caps.Note: Ensure that the main bearings are installed so that the bearing tabs fit into the notch in the main bearing cap.
Illustration 4 g01020434
Position main bearing caps (4) on the crankshaft.Note: Ensure that the numbers on the main bearing caps match the numbers on the cylinder block. Also ensure that the "FRONT" on the main bearing cap is installed toward the front of the cylinder block.
Lubricate the threads of bolts (3) with clean engine oil. Install the bolts.
Tighten bolts (3) for the main bearing caps, as follows:
Tighten Bolt (A) to a torque of 258 14 N m (190 10 lb ft).Note: Bolt (A) is on the bearing tab side of the main bearing cap.
Tighten Bolt (B) opposite the bearing tab side to a torque of 258 14 N m (190 10 lb ft).Note: Bolt (B) is on the opposite side of the bearing tab of the main bearing cap.
Tighten Bolt (B) for an additional 120 5 degrees (2 flats).Note: If Tooling (E) is not used, place an index mark on the bolt and the main bearing cap.
Tighten Bolt (A) for an additional 120 5 degrees (2 flats).Note: If Tooling (E) is not used, place an index mark on the bolt and the main bearing cap.
Rotate the crankshaft to ensure that the crankshaft turns freely.
Illustration 5 g01103661
Use Tooling (D) to check the crankshaft end play. Ensure that Tooling (D) is against a machined surface. The end play is controlled by the thrust plates of No. 4 main bearing (center). Refer to Specifications, "Crankshaft" for the crankshaft end play.Note: Install the connecting rod bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check". Apply clean engine oil on the face of the connecting rod bearings for final assembly.
Illustration 6 g01020428
Position the connecting rod against the crankshaft. Install connecting rod bearing cap (2) on the connecting rod.Note: Ensure that the number on the side of the connecting rod bearing cap is on the same side as the number on the connecting rod. The bearing tabs of the connecting rod bearing cap and the connecting rod are on the side of the piston cooling jet.
Lubricate the threads of bolts (1) with clean engine oil. Install the bolts.
Tighten bolts (1), as follows:
Tighten Bolt (A) and Bolt (C) to a torque of 70 4 N m (52 3 lb ft).
Tighten Bolt (B) and Bolt (D) to a torque of 70 4 N m (52 3 lb ft).
Turn Bolt (B) and Bolt (D) for an additional 60 5 degrees (1/6 turn).Note: If Tooling (E) is not used, place an index mark on each bolt and connecting rod cap.
Tighten Bolt (A) and Bolt (C) to a torque of 70 4 N m (52 3 lb ft).
Turn Bolt (A) and Bolt (C) for an additional 60 5 degrees (1/6 turn).Note: If Tooling (E) is not used, place an index mark on each bolt and connecting rod cap.
Rotate the crankshaft to ensure that the crankshaft turns freely.End By:
Install the piston cooling jets.
Install the flywheel housing.
Install the front housing.