3854801 Volvo.Penta Engine control unit, GSI

start by:a) remove engine and torque dividerb) remove oil pump 1. Remove the nuts and washers from the main bearing cap.2. Remove main bearing cap (1). Remove the lower half of the main bearing from the main bearing cap.
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 center main journal that has no oil hole, put a thin piece of soft material that will not damage the crankshaft journal against the end of the bearing, opposite the tab. Hit the bearing with the soft material until the tab of the bearing is free from the cylinder block. Remove the upper half of the main bearing. 3. Remove the upper half of the main bearing as follows: a) Install tool (A) in the oil hole in the crankshaft.b) Turn the crankshaft in the direction which will push the end of the main bearing with the tab out first. See GUIDELINE FOR REUSABLE PARTS, MAIN AND CONNECTING ROD BEARINGS, Form No. SEBF8009. Install the main bearings dry when the clearance checks are made. Put clean engine oil on the main bearings for final assembly. 4. Install the lower half of the main bearing in the main bearing in the cylinder block with tool (A). Be sure tabs (3) on the back of the bearings fit in the grooves of the cap and cylinder block.5. Put Plastigage (B) on the lower half of the main 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 the main bearing cap is installed with the part number toward the rear of the block and so the number on the bottom of the main bearing cap is the same as the number on the left side of the cylinder block.
Do not use an impact wrench to tighten the bolts the additional 120° 5°.
6. Put clean SAE 30 oil on the threads and face of the main bearing nuts. Install the main bearing cap, washers and nuts. Tighten the nuts to a torque of 60 5 lb.ft. (80 7 N m) in letter sequence A, B, C, D. Put a mark on the nuts and studs, then turn each nut 120 5° more in sequence. Remove the main bearing cap and measure the width of Plastigage (B) which will be the main bearing clearance. The main bearing clearance with a new bearing must be .0058 to .0096 in. (0.147 to 0.244 mm). Maximum permissible clearance with used main bearing is .010 in. (0.25 mm).7. Put clean SAE 30 oil on the threads and face of the main bearing nuts. Put the main bearing cap in the same position on the block as it was removed. Install the washers and nuts and tighten the nuts to a torque of 60 5 lb.ft. (80 7 N m) in letter sequence A, B, C, D as shown in illustration T95333X1. Put a mark on the nuts and studs, then turn each nut 120 5° more in sequence.8. Do Steps 1 through 8 for the remainder of the main bearings. 9. The No. 7 main bearing cap has a thrust bearing on each side of the main bearing cap. The end play of the crankshaft is controlled by the thrust bearings. Check the end play of the crankshaft with tooling (C). The end play must be .010 to .022 in. (0.25 to 0.56 mm). Make a replacement to the thrust bearing if needed. Install the thrust bearing in the groove in the main bearing cap with the aluminum side toward the crankshaft.end by:a) install oil pumpb) install engine and torque divider