809104 Volvo.Penta Disc

Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-9832 Engine Rollover Stand 1
B 138-7576 Link Bracket 2
C Loctite Moly-50 -
D 8T-5096 Dial Indicator Gp 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01124614
Install plugs (11) and tighten to a torque of 50 7 N m (37 5 lb ft).
Position crankshaft gear (10) on the crankshaft and install bolts (9).
Illustration 2 g01124115Note: Install the main bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check". Apply clean engine oil on the main bearings for final assembly.
Install the upper half of main bearing (12) in the cylinder block. Ensure that the main bearing is installed so that the bearing tab fits into the notch in the cylinder block. Coat the main bearing with clean engine oil.Note: The upper half of the main bearing has an oil hole in the center.
Install the upper halves of connecting rod bearings (13) in the connecting rod assemblies. Coat the connecting rod bearing with clean engine oil.
Illustration 3 g01124538
Illustration 4 g01124192
Bolt tightening sequence for the main bearing caps
Note: Ensure that the word "FRONT" that is on the end of the crankshaft is toward the front of the engine.
Attach Tooling (B) and a suitable lifting device to each end of crankshaft (7). The weight of the 3516E crankshaft is approximately 800 kg (1765 lb). Position the crankshaft in the cylinder block.
Place clean engine oil on thrust plates (8). Install thrust plates (8) on each side of the center main bearing.
Install the lower half of the main bearing in the main bearing cap. Ensure that the main bearing is installed so that the bearing tab fits into the notch in main bearing cap (6). Coat the main bearing with clean engine oil.
Coat the underside of the bolt heads and the threads of bolts (5) with clean engine oil. Position main bearing caps (6) and install the bolts and washers. Do not tighten the bolts at this time.Note: The main bearing caps must be installed with the word "FRONT" and the part number toward the front of the engine. Each main bearing cap has a number on the bottom surface and each main bearing must be installed in the corresponding position in the cylinder block.
Tighten bolts (5) in sequence to a torque of 190 14 N m (140 10 lb ft).
Place an index mark on the bolts and the main bearing cap. Tighten the bolts for an additional 180 5 degrees (1/2 turn).
Rotate the crankshaft in order to ensure that the crankshaft turns freely.
Use Tooling (D) to measure the end play of the crankshaft. The end play must not exceed 0.17 to 0.63 mm (0.007 to 0.025inch).
Illustration 5 g01124522
Illustration 6 g01124419
Bolt tightening sequence for the connecting rod caps
Note: Install the connecting rod bearings dry when clearance checks are performed. Refer to Disassembly and Assembly, "Bearing Clearance - Check". Apply clean engine oil on the connecting rod bearings for final assembly.
Install the upper half of the connecting rod bearing on the connecting rod . Ensure that the connecting rod bearing is installed so that the bearing tab fits into the notch in the connecting rod. Coat the connecting rod bearing with clean engine oil. Position the connecting rod onto a journal of the crankshaft.
Install the lower half of the connecting rod bearing on connecting rod cap (4). Ensure that the connecting rod bearing is installed so that the bearing tab fits into the notch in the connecting rod cap. Coat the connecting rod bearing with clean engine oil.Note: The number that is on the side of the connecting rod caps must be installed next to the corresponding number that is on the side of the connecting rod. Install the chamfered side of the connecting rod cap next to the thrust surface of the crankshaft.Note: Reman connecting rods are not numbered for the cylinder position.
Apply Tooling (C) to the threads, the shank, and the seat of bolts (3).
Place connecting rod cap (4) into position. Install bolts (3). Use the following procedure to tighten the bolts:
Tighten Bolt (A) and Bolt (B) to a torque of 90 5 N m (65 4 lb ft).
Tighten Bolt (C) and Bolt (D) to a torque of 90 5 N m (65 4 lb ft).
Tighten Bolt (C) and Bolt (D) again to a torque of 90 5 N m (65 4 lb ft).
Place an index mark on the bolts and the connecting rod cap. Tighten each bolt for an additional 90 5 degrees (1/4 turn).
Rotate the crankshaft in order to ensure that the crankshaft turns freely.
Each counterweight is numbered and must be installed in the same position as the corresponding number on the cranksh