876352 Volvo.Penta Gasket kit

Table 1
Required Tools
Tool Part Number Part Description Qty
A 301-5215 Stud Tensioner Tool Gp 1
8T-3035 Hydraulic Line 1
8T-0820 Hydraulic Pressure Gauge 1
350-7768 Electric Hydraulic Pump
(115 Volt 50/50 Hz) 1
350-7769 Electric Hydraulic Pump
(230 Volt 50/60 Hz) 1
9U-6600 Hand Hydraulic Pump 1
B 8T-0960 Handling Tool Group 1
C 134-0932 Main Bearing Driver 1
D 3P-1529 Circular Level 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g00577576Note: The bearing has a locating tab. When the bearing is viewed from the flywheel, counterclockwise rotation is required for the installation of the upper half of the bearing. Ensure that the tab is properly seated in the groove. Ensure that the tab does not break in the groove.Note: If the main bearing cap bolts were removed, use a tap to clean the threads in the cylinder block prior to the installation of the bolts. Tighten the bolts to a torque of 100 20 N m (75 15 lb ft).
Use a clean cloth to wipe the upper half (1) of the main bearing. Put clean engine oil on the bearing. Use Tooling (C) to roll the upper half of the main bearing into the cylinder block.Note: On the G3612 Engine, the Number 4 main bearing journal does not have an oil hole. Tooling (C) cannot be used to roll the upper half of the main bearing in the cylinder block. To install the Number 4 main bearing, protect the crankshaft and rap the side of the bearing without the tab with a narrow tool.Note: On the G3616 Engine, the Number 5 main bearing journal does not have an oil hole. Tooling (C) cannot be used to roll the upper half of the main bearing in the cylinder block. To install the Number 5 main bearing, protect the crankshaft and rap the side of the bearing without the tab with a narrow tool.
Illustration 2 g00577800
Install thrust plates (2). If necessary, carefully pry the crankshaft to roll the thrust plates into position in the cylinder block.Note: For the G3612 Engine, install the thrust plates on the rear main bearing for rear driven equipment. Install the thrust plates on the front main bearing for front driven equipment.Note: For the G3616 Engine, install the thrust plates on the rear main bearing for rear driven equipment. Install the thrust plates on the front main bearing for front driven equipment.
Illustration 3 g00577801
Use a clean cloth to wipe the lower half (4) of the main bearing and the bore in the main bearing cap. Ensure that there is no thread lubricant on the lower half of the main bearing or on the main bearing cap. Install the lower half of the main bearing in the main bearing cap. Ensure that the tab on the back of the bearing is engaged with the slot in the main bearing cap.
Put clean engine oil on the lower half of the main bearing. Be sure not to put the engine oil on the back side of the bearing.
Use Tooling (B) to raise the main bearing cap on the studs.
Ensure that dowel (3) engages with the hole in the cylinder block. The dowel should extend 10.0 0.5 mm (0.39 0.02 inch) from the main bearing cap.
Install the washers and nuts to hold the main bearing cap. Tighten the nuts by hand. Remove Tooling (B) from the main bearing cap.
Remove the pins from the bearing cap.
Illustration 4 g00577803
Apply engine oil on the face of the washers and the threads of each saddle bolt (5).
Install saddle bolts (5). Do not tighten the saddle bolts on the left side of the engine.
Tighten the saddle bolt on the right side of the engine to a torque of 215 40 N m (160 30 lb ft).
Illustration 5 g00577802Note: Ensure that the threaded collar is inserted into the tensioner cylinder. Ensure that the retainer is installed.
Put the tensioner cylinders and the threaded collars in position on the tray under the main bearing bolts. Put the reaction sleeve in place on the bolt over the main bearing cap nut. Secure the reaction sleeve with the dowel handle.
Fasten the link to the tensioner. Install the spring clips.
Use Tooling (B) to raise the tensioner cylinder off the tray. Place Tooling (D) on the tensioner cylinder. Use the adjusting screws on the Tooling (B) to level the tensioner cylinder. Remove Tooling (D).
Use Tooling (B) to lift the tensioner to the stud. Start the threaded collar onto the stud. Hand tighten the threaded collars on the main bearing cap bolts.
Attach the hoses from the pump to the tensioner cylinders.
Tighten the threaded collar with a 1/2 inch ratchet. The collar should then be loosened 1/4 turn.
Before you operate the pump, ensure that all connections are secure. Ensure that all hoses are in good condition. Oil escaping under high pressure can cause personal injury.