1544120 Volvo.Penta Crankshaft

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that all of the lubrication passages are clean and free of debris.
Clean the seats for the main bearings in the cylinder block and clean the upper main bearings.
Illustration 1 g00541257
Install upper main bearings (8) with the location tabs in the correct position in the cylinder block. Lubricate upper main bearings (8) with clean engine oil.
Illustration 2 g00541256
Ensure that the main bearing journals of crankshaft (7) are clean. Attach lifting straps and a suitable lifting device in order to position the crankshaft in the cylinder block. The weight of the crankshaft is 29 kg (65 lb). Do not scratch any of the finished surfaces on the crankshaft during installation.
Clean the upper thrust washers and lubricate upper thrust washers (9). Place upper thrust washers (9) in the cylinder block on both sides of the center main bearing.
Ensure that the slotted sides of the thrust washers are toward the crankshaft.
Clean the lower main bearings. Install the lower main bearings in the main bearing caps with the location tabs in the correct position. Lubricate the lower main bearing caps with clean engine oil.
Clean the lower thrust washers and lubricate the lower thrust washers. Place the lower thrust washers in the cylinder block.
Illustration 3 g00541253
Ensure that the dowels for main bearing caps (4) are in the correct position in the main bearing caps or in the cylinder block. Install main bearing caps (4) in the position that is marked during the removal process. All of the location tabs on the main bearings should be on the same side. The serial number that is stamped on the main bearing cap should match the number that is stamped on the bottom face of the cylinder block.Note: The connecting rod caps can be held on the connecting rod with two bolts and two nuts. The connecting rod caps can also be held on the connecting rod with two bolts that are threaded into the connecting rod.
Install bolts (3) in main bearing caps (4). Tighten bolts (3) to a torque of 250 N m (185 lb ft).
Illustration 4 g00541254
Install connecting rod caps (6) and connecting rod cap bolts or nuts (5). Tighten the connecting rod caps to the following torque:Nuts on the connecting rod caps ... 125 N m (92 lb ft)Bolts on the connecting rod caps ... 155 N m (114 lb ft)
Illustration 5 g00541499
Illustration 6 g00541498
Illustration 7 g00541252
Clean the bridge and the face of the cylinder block. Apply a thin bead of 8T-9013 Silicone Sealant on the corners of the seat for the bridge. Also apply the sealant around the thread holes in the seat for the bridge. Use the following steps when you apply the 8T-9013 Silicone Sealant to the cylinder block and the bridge.
Apply a 3.0 mm (0.12 inch) bead of 8T-9013 Silicone Sealant along the corner of the top recess in the cylinder block.
Install bridge (2) and the rubber seals, if equipped. The rubber seals will sit higher than the bridge when the seals are correctly installed. Use a straight edge to line up the bridge with the face of the cylinder block. Tighten socket head bolts (1) to a torque of 16 N m (12 lb ft). Tighten the bolts evenly.
When the bridge is positioned and the socket head bolts have been tightened, inject 8T-9013 Silicone Sealant in the groove that are at each end of the bridge. The groove must be completely filled.
When the gasket for the oil pan is removed, damage may occur to the existing seal in the grooves of the bridge. If the seal is damaged, apply a sufficient amount of 8T-9013 Silicone Sealant in order to fill the grooves. Note: Most of the current engines have setscrews that fasten the oil pan to the bridge. The threads of the setscrews have a sealant that is applied by the manufacturer. When the setscrews are installed, ensure that the threads of the socket head bolts and the bridge are clean. Also apply 9S-3263 Thread Lock Compound to the threads of the setscrews. Follow the same process when studs are used instead of the setscrews.End By:
Install the housing for the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft - Install".
Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install".
Install the oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".
Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install".