3803279 Volvo.Penta Injector, exch

Retaining Bolts for the Crankshaft
Illustration 1 g00692899
(1) Allen head screws Tighten the allen head screw to the following torque. ... 27 N m (20 lb ft) (2) Hex head bolts Tighten the hex head bolts to the following torque. ... 27 N m (20 lb ft)Specifications
Illustration 2 g00693067
Typical example for the three cylinder engine (1) ChamferThe chamfer faces the front of the engine. (2) Upper half of the main bearing with the oil groove (3) Upper half of main bearing cap (4) Notch on the upper half of the main bearingThe notch in this position on the bearing cap faces the rear of the engine. This bearing cap is for the No. 2 bearing on three cylinder engines. (5) Connecting rod journal Diameter of connecting rod journal ... 38.964 to 38.975 mm (1.5340 to 1.5344 inch) Service limit ... 38.90 mm (1.5315 inch)Note: If the service limit is exceeded, then the crankshaft must be replaced. (6) Main bearing journal Diameter of main bearing journal ... 45.964 to 45.975 mm (1.8096 to 1.8100 inch) Service limit ... 45.90 mm (1.8071 inch)Note: If the service limit is exceeded, then the crankshaft must be replaced. (7) Lower half of the main bearingThe lower half of the main bearing does not have an oil groove.Measure Wear on the Crankshaft
Illustration 3 g00464232
Measure the crankshaft journals for wear.Measure the diameters of the crankshaft journals that is shown in Illustration 3. This procedure measures wear and eccentricity. Measure the diameters of the connecting rod journals (5) and main journals (6) in positions (1) and (2). Measure the diameter (A) and (B) in each position. (1) (2) Taper The difference between positions (1) and (2) must not be more than the following value. ... 0.05 mm (0.0020 inch) (A) (B) Eccentricity The eccentricity must be the following value or the eccentricity must be less than the following value. ... 0.03 mm (0.0012 inch) Service limit ... 0.06 mm (0.0024 inch)Measure the Main Bearing Clearance
Illustration 4 g00464228
Illustration of the front main bearingMeasure the bore of the main bearings in positions (1) and (2). Measure the bore in the directions (A) and (B) in each position.Refer to the dimensions in this Module "Measure Wear on the Crankshaft". Subtract the smallest diameter of the crankshaft journal from the largest main bearing bore. The remainder is the clearance between the main bearing and the crankshaft journal.Clearance Standard clearance ... 0.039 to 0.106 mm (0.0015 to 0.0042 inch) Service limit ... 0.20 mm (0.0079 inch)If the measurements are outside of the tolerances, the main bearings or the crankshaft must be replaced.The end play is measured on the front main bearing journal. End play of the crankshaft ... 0.05 to 0.30 mm (0.0020 to 0.0118 inch) Service limit ... 0.50 mm (0.0197 inch)Measure the Clearance on the Main Bearing Cap
Main bearing cap 1, main bearing cap 2, and main bearing cap 3 Standard clearance ... 0.039 to 0.092 mm (0.0015 to 0.0036 inch) Service limit ... 0.20 mm (0.0079 inch)Measure the Connecting Rod Bearing Clearance
Illustration 5 g00464231
Measuring the clearance for the connecting rod with a plastigageUse plastigage in order to measure the clearance between the connecting rod journal and the connecting rod bearing.
Cut plastigage (1) to the same width as the bearing. Place the plastigage on the crankshaft journal. Do not place the plastigage on oil hole (2) .
Install the connecting rod and the connecting rod bearing on the crankshaft journal. Refer to the Specifications Module, "Connecting Rod" topic for the tightening procedure and torques.Note: When the connecting rod is installed, never rotate the connecting rod.
Remove the bolts for the connecting rod. Remove the connecting rod. Use the scale that is printed on the bag for the gauge in order to measure the clearance.Note: Measure the widest area of the plastigage.Clearance Standard clearance ... 0.035 to 0.083 mm (0.0014 to 0.0033 inch) Service limit ... 0.20 mm (0.0079 inch)If these measurements are outside of the tolerances, the connecting rod bearing must be replaced.Axial Clearance between the Crankshaft and the Connecting Rod
Clearance Standard clearance ... .01 mm to 0.3 mm (0.0039 to 0.0118 inch) Service limit ... 0.7 mm (0.0276 inch)If the clearance between the bearing and piston pin is not within the tolerance, one or both components must be replaced.Crankshaft Main Bearing Cap
Illustration 6 g00463533
Main bearingRefer to the Specifications Module, "Cylinder Block" topic for additional information about the front crankshaft bearing. (1) Crankshaft Main Bearing Cap BoltTighten the crankshaft main bearing cap bolts on the 3003 engine to the following torque: Bearing cap of aluminum ... 22 N m (16 lb ft) (2) Upper half of bearing cap Standard thickness ... 21.85 to 21.95 mm (0.8602 to 0.8642 inch) Minimum thickness ... 21.60 mm (0.850 inch)One of the halves of the crankshaft bearing has an oil groove. The half of the bearing with the oil groove is installed in the upper half of the bearing cap. (3) Lower half of the bearing cap Standard thickness ... 21.85 to 21.95 mm (0.8602 to 0.8642 inch) Minimum thickness ... 21.60 mm (0.850 inch) (4) DowelTwo dowels are installed in each bearing cap in order to correctly align the two halves of the bearing cap. (5) Retaining bolt for the crankshaft Note: Refer to this Module "Retaining Bolts for the Crankshaft" for the correct torque