11996 Volvo.Penta Gasket

Illustration 1 g02237473
Clean the mounting surface of the gasket.
According to need, apply the sealant to prevent the gasket falling off.
Apply the sealant (three Bond 1211) to the mating surface (1) of the crankcase and main bearing cap, and spread, the sealant evenly.
With aligning to the dowel pin, install the gasket and the front plate.
Tighten the front plate mounting bolts (2) to 12 1 N m (106 95 lb in).Installing camshaft
Note: Be careful not to damage camshaft journals, cams, and camshaft holes during insertion.
Illustration 2 g02237474
Apply engine oil to the camshaft journals and cams.
Slowly insert the camshaft assembly.
Illustration 3 g02237475
(4) Socket P/N:34491-00300
Tighten the thrust plate bolt (3) to 12 1 N m (106 9 lb in).
Make sure that the camshaft rotates lightly. Move the camshaft gear back and forth, and make sure that there is end play.Installing oil pump
Illustration 4 g02237476
Insert the oil pump to the oil pump hole on the crankcase. Then, make sure that the oil pump gear and oil pump drive gear on the camshaft meshes correctly.
From the crankcase side face, tighten the oil pump set bolts (6) with gasket (5) to 34 4 N m (301 35 lb in).Installing oil pan
Illustration 5 g02237477
Clean both side of the oil pan gasket contact surfaces and the contact surfaces of other parts thoroughly.
Apply the sealant (three bond 1212) to the mating surface clearance of the No.1 and No.4 main bearings and crankcase. The filling amount should be approx. 5.0 mm (0.20 inch) protruding from the mating surface clearance (A). Enough to spill out when the oil pan gasket is installed.
Install the oil pan gasket to the crankcase under face, with pushing the gasket circular part into the No.1 and No.4 main bearing cap grooves. Pushing the gasket protrusion into the mating surface clearance where sealant is filled.
For press oil pan tighten the mounting bolts (7) to 8 1 N m (71 9 lb in). For cast oil pan tighten the mounting bolts (7) to 30 3 N m (22 2 lb ft).Inverting crankcase
Note: Do not place the engine directly on the ground. It causes cracking the oil pan.
Illustration 6 g02315855
Attach the wire rope to the crankcase. Using a crane, hoist the crankcase and lay the crankcase with side faced downwards.
After that, hoist the crankcase again and invert the crankcase.Installing front idler gear
Illustration 7 g02237479
Timing gear train (8) Crankshaft gear (9) Inspection pump gear (10) Idler gear (11) Camshaft gear
Apply engine oil to the idler gear shaft (13) .
Install the idler gear with all match marks on it aligned with the marks on the other gears.
Illustration 8 g02237481
Install the thrust plate (12) with hole matching the pin of the idler gear shaft.
Tighten the thrust plate bolt to the specified torque.
Move the idler gear back and forth, and make sure that there is end play.Inspecting and adjusting timing gear after installation
Illustration 9 g02237482
Be sure to inspect and adjust the timing gear when the timing gear has been reassembled.
Table 1
Item     Standard     Limit    
Backlash     Crankshaft gear to idler gear    
0.030 to 0.160 mm (0.0012 to 0.0063 inch)    
0.250 mm (0.0098 inch) &