382809 Volvo.Penta Lock washer

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
C 8T-0960 Handling Tool Group 1
D 134-0932 Main Bearing Driver 1
E 3P-1529 Circular Level 1
(1) Operating pressure is 65000 2400 kPa (9425 348 psi).
(2) Operating pressure is 111500 3950 kPa (16170 575 psi).
(3) Three hydraulic pumps are listed. Only one pump is necessary in order to carry out the job.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g03310579Note: 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.
Use a clean cloth in order to wipe the upper half (1) of the main bearing. Put clean engine oil on the bearing. Use Tooling (D) in order to roll the upper half of the main bearing into the cylinder block. Note: On the 3612 Engine, the Number 4 main bearing journal does not have an oil hole. Tooling (D) cannot be used in order to roll the upper half of the main bearing in the cylinder block. In order to install the Number 4 main bearing, protect the crankshaft and rap the side of the bearing with the tab with a narrow tool.Note: On the 3616 Engine, the Number 5 main bearing journal does not have an oil hole. Tooling (D) cannot be used in order to roll the upper half of the main bearing in the cylinder block. In order to install the Number 5 main bearing, protect the crankshaft and rap the side of the bearing with the tab with a narrow tool.
Illustration 2 g00577800
Install the thrust plates (2). If necessary, carefully pry the crankshaft in order to roll the thrust plates into position in the cylinder block. Note: For the 3612 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 3616 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 g03310597
Use a clean cloth in order 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 (C) in order to raise the main bearing cap on the studs. The weight of the main bearing cap is 70 kg (155 lb).
Ensure that the 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.
Illustration 4 g00644760
Put engine oil on the face of the washer and the threads of each saddle bolt (9).
Install the saddle bolts (9) about four turns in.
Install the washers and nuts in order to hold the main bearing cap. Tighten the nuts by hand. Remove Tooling (C) from the main bearing cap.
Remove the pins from the bearing cap.
Illustration 5 g00644724Note: The 4C-5816 Collar Retainer, the 8T-0895 Stud Tensioner Cylinder and the 4C-5817 Threaded Collar are parts of Tool (A).
Place 4C-5816 Collar Retainer (7) on top of 8T-0895 Stud Tensioner Cylinder (6) in order to determine the bolts that need to be removed from the tensioner cylinder. Remove the four appropriate bolts from the cylinder.
Insert 4C-5817 Threaded Collar (5) in the center of tensioner cylinder (6).
Install collar retainer (7) in order to retain threaded collar (5) in tensioner cylinder (6).
Use six bolts (8) in order to fasten retainer (7) to