20586604 Volvo.Penta Big-end bearing kit

The rocker shafts and push rods do not have to be removed to remove the crankshaft but bent push rods can be the result if they are not removed.
1. Put the engine in the position as shown. The weight of the engine is approximately 5443 kg (12,000 lb).2. Remove counterweights (1) from the crankshaft. 3. Remove bearing caps (2) from the connecting rod and push the connecting rods away from the crankshaft. Use wire to hold the upper half of the connecting rods away from the crankshaft. 4. Remove the center main bearing cap and remove two thrust plates (3) from each side of the main bearing. 5. Use two of the bolts that hold the flywheel to the crankshaft and install a bolt in each end of the crankshaft. Fasten straps and a suitable lifting device to the crankshaft as shown.6. Remove the remainder of main bearings caps (5) and remove crankshaft (4) from the engine block. The weight of the crankshaft is 454 kg (1,000 lb). 7. If necessary, remove bolts (7) to remove gears (6) from each end of the crankshaft.Install Crankshaft
1. If gears (1) were removed, install gears (1) on each end of the crankshaft and install the bolts to hold the gears. 2. Make sure the upper halves of main bearings (2) (bearings with oil holes) are in position in the cylinder block.3. Put the upper halves of the rod bearings in position in the connecting rod assemblies. Install the bearings dry when clearance check are made. Put clean engine oil on the bearings for final assembly.If the crankshaft journals and bores for the block and rods were measured at disassembly and found to be within specifications, no further checks are necessary. However, if the serviceman still wants to measure the bearing clearances, Plastigage is recommended. Lead wire, shim stock or use of a dial bore gauge can damage the bearing surface.The serviceman must be very careful to use Plastigage correctly. The following points must be remembered:...Make sure that the backs of the bearings and the bores are clean and dry....Make sure that the bearing locking tabs are properly seated in their slots....The crankshaft must be free of oil where the Plastigage touches it....If the main bearing clearances are checked with the engine upright or on its side, the crankshaft must be supported. Use a jack under an adjacent crankshaft counterweight and hold the crankshaft against the crown of the bearing. If the crankshaft is not supported, the weight of the crankshaft will cause incorrect readings....Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing....Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed....Do not turn the crankshaft with the Plastigage installed....Carefully remove the cap but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements....Remove the Plastigage before reinstalling the cap.When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004 in) the readings may be low by 0.013 to 0.025 mm (.0005 to .0010 in). Out-of-round journals can give faulty readings. Also, journal taper may be indicated when one end of the Plastigage is wider that the other. For complete details concerning measuring bearing clearances, see Engine Bearings & Crankshafts, Form No. SEBD0531. Make sure the word "FRONT" on the end of the crankshaft is toward the front of the cylinder block when the crankshaft is installed.4. Fasten straps and a suitable lifting device to crankshaft (3) with two flywheel bolts and put it in position. The weight of the crankshaft is 454 kg (1,000 lb).5. If necessary, check the main bearing clearances with Plastigage as follows:a. Make sure the main bearings are in position in the main bearing caps. Make sure tab on the back of the bearing is in position in the tab groove in the main bearing cap.b. Put a piece of Plastigage in position on the crown of the crankshaft. The main bearing caps must be installed with the word front and the cast part number toward the front of the cylinder block. Each cap has a number on the bottom surface and must be installed in the same position as the correct number on the side of the block pan rail.c. Put 6V4876 Molykote Paste Lubricant on the thread of the main bearing cap bolts.d. Put the main bearing caps in position, and install the bolts that hold them. Tighten the bolts in the number sequence shown to a torque of 136 14 N m (100 10 lb ft). Hand tighten each bolt again in the number sequence 180 5 degrees (1/2 turn) more. Do not turn the crankshaft when the Plastigage is in position.e. Remove the main bearing caps, and measure the Plastigage. The main bearing clearance must be 0.122 to 0.241 mm (.0048 to .0095 in). 6. Put clean engine oil on thrust plates (8). Install thrust plates (8) on each side of the center main bearing.7. Put the main bearing caps in position, and tighten the bolt as in Step 5d.8. Check the crankshaft end play with Tool (A). The end play must be 0.17 to 0.63 mm (.007 to .025 in). 9. Remove the wire that holds the upper half of the connecting rods in place. Pull the connecting rod and piston assemblies into position against the crankshaft. Install the connecting rod bearings dry when clearance checks are made. Put clean engine oil on the connecting rod bearings