22081338 Volvo.Penta Kit

Table 1
Required Tools
Tool Part Number Part Description Qty
A 207-5034(1) Stud Tensioner Tool Gp 1
301-5215(2) Stud Tensioner Tool Gp 1
B 8T-3035 Hydraulic Line 1
8T-0820 Hydraulic Pressure Gauge 1
3S-6224(3) Electric Hydraulic Pump
(115 Volt 50/50 Hz) 1
8S-8033(3) Electric Hydraulic Pump
(230 Volt 50/60 Hz) 1
9U-6600(3) Hand Hydraulic Pump 1
D 8T-0960 Handling Tool Gp 1
E - Guide Studs
1/2 - 13 by 5 inch 4
(1) Operating pressure is 65000 2400 kPa (9425 348 psi).
(2) Operating pressure is 111500 3950 kPa (16170 575 psi).
(3) There are three pumps that are listed in the tool chart. Only one pump is required for the procedure.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Clean the crankshaft.
Clean the crankshaft main bearings. Refer to Reuse and Salvage Guidelines, SEBF8009, "Main And Connecting Rod Bearings" for additional information.
Clean the cylinder block.
If the studs were removed, tighten the studs for the main bearing cap to a torque of 100 20 N m (75 15 lb ft).
Put 50 mm (2.0 inch) plastic sleeves on the main bearing studs in order to prevent damage to the crankshaft during the removal procedure.
Illustration 1 g01315342
Put upper halves (5) of the main bearings into position in the cylinder block. Ensure that the tab on the back of the main bearing is engaged with the slot in the cylinder block.
Apply clean engine oil to the main bearings.
Be sure to identify the front of the crankshaft and the rear of the crankshaft. The front center hub of the crankshaft is stamped with "FRT".
The rear of the crankshaft is identified by three holes in the flange.
Attach a suitable lifting device to each end of the crankshaft. The weight of the 3606 crankshaft is approximately 1800 kg (3970 lb). The weight of the 3608 crankshaft is approximately 2400 kg (5300 lb). Position the crankshaft below the cylinder block.
Raise the crankshaft into position in the upper half of the main bearing. Use a technician on each end of the crankshaft in order to guide the crankshaft past the main bearing studs.
Remove the plastic sleeves from the main bearing studs.
Install the lower half of the main bearing in the Number 5 main bearing cap for 6 cylinder engines. Install the lower half of the main bearing in the Number 7 main bearing cap for 8 cylinder engines. Ensure that the tab on the back of the main bearing is engaged with the slot in the main bearing cap.
Apply clean engine oil to the main bearing.
Illustration 2 g01315344
Put the Number 5 main bearing cap in position for 6 cylinder engines. Put the Number 7 main bearing cap in position for 8 cylinder engines. The cylinder number is on the bottom of the main bearing cap. Ensure that the number is facing toward the front of the cylinder block. Note: Ensure that the main bearing caps are installed in the original positions. Ensure that the numbers that are stamped on the main bearing caps and the numbers that are on the left side of the oil pan are identical.
Use Tooling (D) in order to raise main bearing cap (6) on the studs. The weight of each main bearing cap (6) is approximately 65 kg (145 lb).
Ensure that dowel (7) engages with the hole in the cylinder block.
Illustration 3 g01315341
Install washers (8) and nuts (9). Tighten the nuts by hand.
Repeat Step 13 through Step 18 for the Number 3 main bearing cap.
Lower Tooling (D).
Illustration 4 g01315343
Illustration 5 g01315340Note: Install rear thrust plate (3) on the rear main bearing for rear driven equipment. Install front thrust plate (4) on the front main bearing for front driven equipment. If necessary, pry the crankshaft in order to install the thrust plates. Be extremely careful not to contact any of the finished surfaces.
Apply clean engine oil to the thrust face of rear thrust plate (3). Roll the thrust plate into position in the cylinder block.
Apply clean engine oil to the thrust face of front thrust plate (4). Roll the thrust plate into position in the cylinder block.
Install the remainder of the main bearing caps. Be sure to follow the procedure that was given in Step 13 through Step 18.
Install the bracket for the crankshaft timing pin.