3594603 Volvo.Penta Wiring harness

Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-9832 Engine Roll-Over Stand 1
B 8S-2328 Dial Indicator 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g00577546
If crankshaft gears (1) are removed, install the gears on crankshaft (2).
Check the clearance of the bearings. Refer to Disassembly and Assembly, "Bearing Clearance - Check" for the correct procedure.
Illustration 2 g00577547Note: Place clean engine oil on the main bearings and on the connecting rod bearings prior to installation.Note: The upper halves of the main bearings have an oil hole in the center.
Install the upper halves of main bearings (3) in the cylinder block.
Install the upper halves of connecting rod bearings (4) in the connecting rod assemblies.
Illustration 3 g00577548
Typical example
Note: Ensure that the word "FRONT" that is on the end of the crankshaft is toward the front of the engine.
Attach a suitable lifting device to crankshaft (2) and position the crankshaft in the cylinder block.
Illustration 4 g00577550
Tightening sequence
Note: The main bearing caps must be installed with the word "FRONT" and the part number toward the front of the engine. Each main bearing cap has a number on the bottom surface and each main bearing must be installed in the corresponding position in the cylinder block.
Lubricate the threads of the bolts for the main bearing caps with clean engine oil.
Place clean engine oil on thrust plates (9). Install thrust plates (9) on each side of the center main bearing.
Illustration 5 g00577577
Place the main bearing caps into position and install the bolts. Tighten the bolts in the numerical sequence that is shown above to a torque of 190 14 N m (140 10 lb ft). Tighten the bolts again for an additional 180 5 degrees.
Check the end play with Tool (B). The end play must not exceed 0.40 0.23 mm (0.0157 0.0091 inch).
Illustration 6 g00577579
Position the connecting rods on the journals of the crankshaft.Note: The number that is on the side of the connecting rod caps must be installed next to the corresponding number that is on the side of the connecting rod.
Illustration 7 g00577581
Tightening sequence
Place 6V-4876 Lubricant on the bolts for the connecting rod caps.
Place connecting rod caps (10) and install the bolts. Tighten the bolts with the following steps:
Tighten bolts (11) and (12) to a torque of 90 5 N m (65 4 lb ft).
Tighten bolts (13) and (14) to a torque of 90 5 N m (65 4 lb ft).
Tighten bolts (11) and (12) again to a torque of 90 5 N m (65 4 lb ft).
Tighten bolts (13) and (14) again to a torque of 90 5 N m (65 4 lb ft).
Tighten each bolt for an additional 90 5 degrees (1/4 turn). An impact wrench may be used.
Place the remaining connecting rod caps in position and tighten the bolts with the same procedure that is in Steps 12a through 12e.
Illustration 8 g00577584
Each counterweight is numbered and must be installed in the same position as the corresponding number on the crankshaft mounting pad in order to prevent damage to the crankshaft.
Install counterweights (15) and use the correct tightening procedure below.
The following procedure is for the installation of the counterweights in G3508 Engines.
Ensure that the dowels are in the correct position and install the counterweights on the crankshaft.
Apply 6V-4876 Lubricant to the threads of the bolt, to the shank of the bolt, and to the seat of the bolt prior to assembly.
Tighten the bolts in all the counterweight to a torque of 200 5 N m (150 4 lb ft).