863147 Volvo.Penta Cover

1. Remove bolts (1) that hold main bearing caps (2) to the block, and remove main bearing caps (2). 2. Install one of the bolts from the front pulley in each end of the crankshaft.3. Fasten a hoist to crankshaft (3), and remove crankshaft (3) from the block. The weight is 159 kg (350 lb.). If new main bearings are not to be installed, keep old bearings with identification as to their location in cylinder block. 4. Use tooling (A) to remove the crankshaft gear.5. Use tooling (B) if necessary to remove the dowel and the pin.Install Crankshaft
1. Install pin (1) in the crankshaft end until it is extended from the surface 6.4 0.5 mm (.25 .02 in.).2. Install dowel (2) until it is extended from the surface 4.1 0.5 mm (.16 .02 in.). 3. Heat crankshaft gear (3) to a maximum temperature of 232°C (450°F). Install gear (3) on the crankshaft with the keyway in alignment with dowel (2) and the "V" mark to the outside. The dowel in the crankshaft must be in alignment with the keyway in crankshaft gear (3).4. Clean the cylinder block and main bearing caps thoroughly. Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearings for final assembly. 5. Install upper half of main bearings (4) in the block. 6. Install one bolt for the flywheel on each end of the crankshaft.7. Fasten a hoist, and put crankshaft (5) in position in block. Be sure the "V" mark on the crankshaft gear is in alignment with "V" mark on the idler gear. The "K" marks on the camshaft gear can be seen at the outer edges of the idler gear when the timing gears are in the correct position.8. Install main bearings in bearing caps. Be sure tabs (6) on back of the bearings fit in the tab slots of the caps and cylinder block.9. Use Plastigage (B) to check bearing clearance.10. Put Plastigage (B) on the bearing.
Be sure main bearing caps (7) are installed so the numbers on the side of the cylinder block are the same as the numbers on the bearing caps, and the arrows on the caps are toward the front of the cylinder block.
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 with a force equal to the weight of the crankshaft and held against the upper halves of the main bearings to get a correct measurement with Plastigage (B). 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 the crankshaft when Plastigage (B) is in position to check the clearance.
Do not use an impact wrench to tighten the bolts the additional 120° 5° when the bearing clearance is being checked.
11. Install the main bearinga caps. Install bolts (8), and tighten the bolts at the end with tab first to a torque of 260 14 N m (190 10 lb.ft.). Put a mark on the bolts and caps. Turn the bolts at the opposite end of the tab first an extra 120° 5° from the mark.12. Remove the main bearing caps. Remove Plastigage (B) from the caps. Check the width of Plastigage (B) to find the bearing clearance. The bearing clearance must be 0.091 to 0.185 mm (.0036 to .0073 in.) with new bearings. Maximum clearance with used bearings is 0.25 mm (.010 in.).13. Install the thrust bearings for No. 4 main bearing. Install the thrust bearings with the side identification "BLOCK SIDE" toward the cylinder block.14. Put clean engine oil on the threads of the bolts. Install the main bearing caps. Install the bolts, and tighten the bolts at the end with the tab first to a torque of 260 14 N m (190 10 lb.ft.). Put a mark on the bolts and caps. Turn the bolts, opposite end of the tab first, an extra 120° 5° from the mark. 15. Check the end play of the crankshaft with tool group (A). Be sure the dial indicator is against a machined surface. The end play is controlled by the thrust bearings of No. 4 (center) main bearing. The end play with new bearings must be 0.15 to 0.51 mm (.006 to .020 in.). The maximum permissible end play with used bearings is 0.89 mm (.035 in.).END BY:a. install pistons and connecting rod assembliesb. install flywheel housingc. install timing gear coverd. install crankshaft front seal and wear sleevee. install crankshaft rear seal and wear sleeve.