826805 Volvo.Penta Cover

start by:a) remove engine oil coolerb) remove water pumpc) remove engine oil pumpd) remove oil pressure relief valvee) remove gas pressure regulator 1. Remove the bolts (1) that hold inspection covers to block. Remove inspection covers (2) from each side of block. 2. Remove the nuts for main bearing caps with wrench (B). Remove the bearing cap with lower half of bearing. 3. Use tool (A) to move out the upper half of main bearing as the crankshaft is turned in the normal direction of rotation.
If the crankshaft is turned in the wrong direction, the tab of the bearing will be pushed between the crankshaft and cylinder block. This can cause damage to either or both.
On the bearing journal that has no drilled hole, put a thin piece of fiber, hardwood or plastic against end of bearing opposite tab. Hit the bearing lightly with the above until tab of bearing is free from cylinder block. Remove the upper half of bearing.Install Crankshaft Main Bearings
Install the main bearings dry when the clearance checks are made. Put clean engine oil on the main bearings for final assembly.1. Use tool (A) to install upper half of bearing in cylinder block. The bearing with oil hole is upper half.2. Clean main bearing caps and install lower halves of bearings in caps. When the bearing clearance is checked and the engine is in a vertical position, such as in the vehicle, the crankshaft will have to be lifted up and held against the upper halves of the main bearings to get a correct measurement with Plastigage. The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, such as on an engine stand, it is not necessary to hold the crankshaft up. Do not turn crankshaft when Plastigage is in position to check clearance.
Do not use an impact wrench to tighten the bolts the additional 120°.
3. Use Plastigage (C) to check bearing clearance. Install caps and tighten both nuts with tool (B) to 200 10 lb.ft. (270 14 N m). Put a mark on nuts and end of studs. Tighten nuts 120° from the mark. Remove caps and check thickness of Plastigage (C) to find bearing clearance. Bearing clearance must be .0048 to .0090 in. (0.122 to 0.229 mm) for new parts. Maximum permissible clearance for used parts is .015 (0.38 mm). Main bearing caps have numbers as to their location in cylinder block. Install bearing caps so the number on cap is same as number on cylinder block. Both numbers must be on same side of cylinder block.4. Put clean engine oil on threads of studs and seat for nut. Install main bearing caps and nuts. Install thrust plates on dowels on rear cap. The dowels must not be extended more than .160 in. (4.06 mm) from counterbore face of bearing cap. Tighten nuts with wrench (B) to 200 10 lb.ft. (270 14 N m). Put a mark on nuts and ends of studs. Tighten nuts an extra 120° from mark.5. Use indicator group (D) to check end play of crankshaft as controlled by thrust plates. End play with new parts must be .005 to .021 in. (0.13 to 0.53 mm). Maximum permissible end play with used parts is .035 in. (0.89 mm).6. Install the inspection covers.end by:a) install gas pressure regulatorb) install oil pressure relief valvec) install engine oil pumpd) install water pumpe) install engine oil cooler