40005634 Volvo.Penta Control panel

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     138-7573     Link Bracket     2    
B         Plastigage        
C     8T-5096     Dial Indicator     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g00515189
Install pin (1) in the crankshaft. The length of the pin out of the crankshaft face is 8.4 mm (0.33 inch).
Install dowel (2) in the crankshaft. The length of the dowel out of the crankshaft surface is 4.1 0.5 mm (0.16 0.02 inch).
Illustration 2 g00568027
Heat crankshaft gear (3) to a maximum temperature of 205 °C (400 °F). Install gear (3) on the crankshaft with the keyway in alignment with dowel (2). The timing mark "V" is toward the outside of the crankshaft. The notch in the gear must be in alignment with the dowel in the crankshaft.
Clean the cylinder block and the main bearing caps thoroughly.Note: Install the main bearings dry when clearance checks are made. Put clean engine oil on the main bearing for final assembly.
Illustration 3 g00568037
Install the upper half of main bearing (5) in the cylinder block. Ensure that the main bearings are installed so that bearing tabs fit into the notch in the cylinder block and in the main bearing caps. Install the upper half of connecting rod bearing (4) in the connecting rod.
Illustration 4 g00568051
Install Tool (A) on each end of the crankshaft with a front pulley bolt.
Fasten a hoist to the crankshaft (6). Install the crankshaft in the cylinder block.
Illustration 5 g00568153
Be sure that the "V" timing marks are aligned on idler gear (8) and crankshaft gear (7) .
Illustration 6 g00568504
Note: Install the thrust plates with the identification "Block Side" toward the cylinder block.
Put clean engine oil on thrust plates (9). Install thrust plates (9) next to the center main bearings.
Illustration 7 g00568512
Install the lower half of the main bearing (10) in the main bearing cap (11) .Note: Refer to Special Publication, SEBD0531, "Engine Bearings and Crankshafts" for complete details concerning measuring of bearing clearances.
Check the bearing clearances with Tool (B). Put Tool (B) on the bearing surfaces.Note: Ensure that the numbers on the main bearing caps match the numbers on the cylinder block. The arrows on the main bearing caps are toward the front of the cylinder block.
Install the main bearing caps. Put 4C-5593 Anti-Seize Compound on the bolts. Install the bolts in the main bearing caps. Tighten the bolt on the tab end of the main bearing cap. Next, tighten the other main bearing cap bolt. Tighten all bolts to a torque of 258 14 N m (190 10 lb ft).
Illustration 8 g00285128
Put a mark on each bolt and each main bearing cap. Tighten the bolt opposite the tab end of the main bearing cap 120 5 degrees further. Next, tighten the bolt on the tab end of the main bearing cap 120 5 degrees further.
Remove the main bearing caps. Measure the thickness of Tool (B). Remove Tool (B) from the main bearing caps. This measurement is the main bearing clearance. The bearing clearance must be 0.091 to 0.186 mm (0.0036 to 0.0073 inch) with new main bearings. Maximum clearance with used main bearings is 0.25 mm (0.010 inch).
Put clean engine oil on the bolts and threads. Install the bolts in the main bearing caps. Tighten the bolt on the tab end of the main bearing cap. Next, tighten the other main bearing cap bolt. Tighten all nuts to a torque of 258 14 N m (190 10 lb ft). Put a mark on each bolt and each main bearing cap. Tighten the bolt opposite the tab end of the main bearing cap 120 5 degrees further. Next, tighten the bolt on the tab end of the main bearing cap 120 5 degrees further.