421215 Volvo.Penta Gasket

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     8T-5096     Dial Indicator Gp     1    
B     8T-9022     Silicone Gasket     -    
C     198-9113     Seal Installer     1    
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.
Illustration 1 g01358194
Install upper main bearings (6). The bearing tabs for the upper main bearings must be located in the correct position in the cylinder block. Lubricate upper main bearings (6) with clean engine oil.
Lubricate the upper half of the thrust washer. Place the upper half of the thrust washer on the rear of the cylinder block with the oil grooves toward the outside.
Illustration 2 g01033376
Ensure that the main bearing journals and the connecting rod bearing journals of the crankshaft are clean. Attach a suitable lifting device in order to position crankshaft (5) in the cylinder block. The weight of the crankshaft is approximately 32 kg (70 lb).Note: Be careful not to damage the finished surfaces on the crankshaft.
Lubricate the lower half of the thrust washers. Place the lower half of the thrust washers on both sides of the rear main bearing cap. The grooves on the thrust washers must be positioned toward the crankshaft.
Illustration 3 g01041202
Clean the lower main bearings. Install lower main bearings (7) in main bearing caps (2) with the bearing tabs in the correct position. Lubricate the lower main bearing caps with clean engine oil.
Ensure that locating dowels (8) for main bearing caps (2) are in the correct position in the main bearing caps or in the cylinder block.
Install main bearing caps (2) in the position that was marked during the removal process. All of the bearing tabs for the main bearings should be on the same side. Install main bearing cap bolts (1) and tighten finger tight.Note: Do not install the rear main bearing cap yet.
Illustration 4 g01033393
Apply Tooling (B) to the corners of the rear main bearing cap. Install the rear main bearing cap to the cylinder block so that the rear face is even with the rear face of the cylinder block.
Illustration 5 g01033394
Apply soapy water to side seals (9). Position side seals (9) in the grooves on the rear main bearing cap with the rounded edges of the seals toward the outside. Use Tooling (C) to push the seal into position in order to reduce the risk of damaging the seal's metal core. Apply Tooling (B) around side seals (9) .
Install the bolts for the rear main bearing cap. Tighten all of the bolts for the main bearing caps to a torque of 98 to 108 N m (72 to 80 lb ft).
Ensure that the upper connecting rod bearings are centered in the connecting rod. Ensure that the lower connecting rod bearings are centered in the connecting rod cap. Lubricate the bearing faces with clean engine oil.Note: Remove the tape or rubber tubing on the connecting rod bolts.Note: Ensure that the mark on the connecting rod cap matches the mark on the connecting rod. Ensure that the marks are on the same side.
Install connecting rod caps (4). Install nuts (3) and tighten to a torque of 49 to 59 N m (36 to 44 lb ft).
Rotate the crankshaft in order to ensure that the crankshaft turns freely.
Check the crankshaft end play. Use a prybar to move the crankshaft toward the front of the engine. Use Tooling (A) to measure the end play. The maximum permissible crankshaft end play is 0.300 mm (0.0118 inch).End By:
Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housng - Remove and Install".
Install the front housing. Refer to Disassembly and Assembly, "Housng (Front) - Install".
Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".