3825724 Volvo.Penta Cap, with level guard outlet

Start By: a. remove oil pumpb. remove timing gear coverc. remove flywheel housingd. remove pistons For more detail about removal of main bearings, see Remove And Install Crankshaft Main Bearings. 1. Check each bearing cap (1) for its location on the engine. Each cap has an arrow which is toward the front of the block and a number which gives the location of that cap. Keep each bearing with the correct cap.2. Remove bearing caps No. 2 through No. 6. Remove the thrust plates from No. 4 upper bearing.3. Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft as shown. Remove No. 1 and No. 7 main bearing caps. Remove the crankshaft. Weight of the crankshaft is 181 kg (400 lb.).
Be careful not to damage the crankshaft journals when the crankshaft is removed.
4. Remove crankshaft gear (2) with tooling (A). 5. Remove dowel (4) and pin (3) from the crankshaft with tooling (B).6. If necessary remove the plugs from the crankshaft. The following steps are for the installation of the crankshaft.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, tool (B) 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.... 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.... 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.... 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") the readings may be low by 0.013 to 0.025 mm (.0005 to .0010"). 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 And Crankshafts, Form No. SEBD0531. Do not put oil on the bearings until the bearing clearance has been checked.7. If any of the plugs were removed, install them into the crankshaft to a minimum depth of 2.54 mm (.100 in.) and with a minimum torque of 23 N m (17 lb.ft.). Stake (make a mark with a punch) the crankshaft to hold the plug tight.8. Install pin (3) in the crankshaft end until it is extended from the surface to a maximum distance of 6.4 mm (.25 in.).9. Install dowel (4) until it is extended from the surface a distance of 4.1 0.5 mm (.16 .02 in.) 10. Heat gear (2) to a maximum temperature of 233° C (451° F). Gear (2) must be installed on the crankshaft with the "V" timing mark toward the outside.11. Install gear (2) on the crankshaft. Make sure the notch in the gear is in alignment with the dowel on the crankshaft. Do not put oil on the bearings until the bearing clearance has been checked.12. Install the bearings in the cylinder block. Make sure the tab in each bearing is in alignment with the notch in the cylinder block.13. Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft and put it in position on the block.
Use care to prevent damage to the crankshaft journals. Make sure the "V" mark on the crankshaft gear is in alignment with the "V" mark on the idler gear.
The side of each thrust plate (5) with the words "BLOCK SIDE" must be installed with this side toward the cylinder block.14. Put clean oil on thrust plates (5). Install thrust plates (5) next to the center main bearings. Do not put oil on bearings (6) until the bearing clearances have been checked.15. Put bearings (6) in their original position in crankshaft main bearing caps (7).16. Check the crankshaft main bearing clearance with Plastigage as follows: a. Put a piece of Plastigage between the crankshaft bearing journal surface and bearing (6).b. Install the crankshaft main bearing caps (7) with the arrow on each cap toward the front of cylinder block. Each crankshaft main bearing cap has a number on the bottom surface and must be installed in the same position as the correct number on the left side of the cylinder block.c. Put 2P2506 Thread Lubricant on the threads of the cap bolts. Install the cap bolts finger tight.d. Tighten the bolts on the tab end of the caps first to