21640262 Volvo.Penta Emergency stop

1. Fasten tool (A) to the engine and put the engine in position as shown.2. Check the connecting rods and the caps for their identification and location.3. Remove nuts (2) and caps (1) from the engine.4. Carefully move the connecting rods away from the crankshaft. 5. Check the bearing caps for a number as to their location. If a number can not be seen, put a number on the side of cylinder block and bearing cap.6. Remove bolts (3) and bearing caps (4) from the engine. 7. Remove thrust bearings (5) from each side of No. 4 crankshaft main bearing. 8. Fasten tooling (B) and a hoist to crankshaft (6) and remove it from the engine. The weight of the crankshaft is 159 kg (350 lb.). 9. Use tooling (C) and remove outer gear (7) from the crankshaft.10. Use a hammer and a chisel to remove the spacer from the crankshaft. 11. Use tooling (D) to remove the dowel from the crankshaft.12. Use tooling (C) to remove inner gear (8) from the crankshaft. 13. Remove crankshaft main bearings (9) from the cylinder block. If new main bearings are not to be installed, keep old bearings with identification as to their location in the cylinder block.Install Crankshaft
1. If dowel (1) was removed from crankshaft (2), install it in the flywheel end of the crankshaft to a maximum dimension of 6.4 mm (.25 in.).2. Heat the crankshaft gears to a maximum temperature of 230°C (446°F).3. The centerline of inner gear key way must be in alignment with the centerline of the dowel hole within 0.51 mm (.020 in.). Install crankshaft inner gear (4) on the crankshaft.4. Install the spacer on the crankshaft.5. Install the dowel in the crankshaft. The dowel must be extended no more than 4.1 0.5 mm (.16 .02 in.) from the surface of the crankshaft. The dowel in the crankshaft must be in alignment with the notch in crankshaft gear (3).6. Make sure the "V" mark on the crankshaft gear is toward the outside and install crankshaft gear (3).7. 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. 8. Install upper half of main bearings (5) in the cylinder block. Make sure the tabs on the back of the bearings fit in the grooves of the cylinder block.9. Fasten tooling (A) and a hoist to each end of crankshaft (2) as shown.10. Put crankshaft (2) in position in the cylinder block. 11. Make sure the "V" mark on crankshaft gear (3) is in alignment with "V" mark on idler gear (6). 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. Thrust bearings (7) have a side marked "BLOCK SIDE" and must be installed toward the cylinder block. 13. Install main bearings (10) in bearing caps (9). Be sure tabs (8) on the back of bearings fit in the grooves of the caps.14. Use Plastigage (C) to check bearing clearance.15. Put Plastigage (C) on the bearing. 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 crankshaft when Plastigage is in position to check clearance.
Be sure main bearing caps (9) 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.
16. Install main bearing caps (9) on the engine with bolts (10).
Do not use an impact wrench to tighten the bolts the additional 120° 5°.
17. Tighten bolts (10) tab end 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 opposite end of tab first an extra 120° 5° from the mark.18. Remove the main bearing caps. Remove Plastigage (C) from the caps. Check the thickness of Plastigage (C) 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.).19. Put clean engine oil on the threads of the bolts. Install the main bearing caps. Install the bolts and 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 tab first, an extra 120° 5° from the mark. 20. Install connecting rod bearing caps (11) on the connecting rods. For the correct installation procedure, see REMOVE AND INSTALL CONNECTING ROD BEARINGS. 21. Check the end play of the crankshaft with tool group (B). Be sure the dial indicator is against a machined surface. Then 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.).START BY:a) install timing gear coverb) install flywheel housingc) install oil pump