877616 Volvo.Penta Overhaul kit, cylinder head

start by:a) remove oil pan plateb) remove oil pump 1. Remove Nos. 5, 3 and 1 main bearing caps (1). Remove the lower halves of the main bearings from the caps. Remove the crankshaft thrust bearings from the No. 5 main.
If the crankshaft is turned in the wrong direction, the tab on main bearing will be pushed between the crankshaft and bearing area in the block which can cause damage to the block or crankshaft.
2. Install tool (A) in the oil hole in the crankshaft journal and remove upper main bearing halves (2) as the crankshaft is turned and the bearing is moved out of the cylinder block. Install the main bearings dry when the clearance checks are made. Put clean engine oil on the main bearings for final assembly.
Make sure the upper and lower halves of the main bearings are installed so the bearing tabs fit into the notch in cylinder block and the main bearing caps.
3. Use tool (A) and install the upper main bearing halves (3) in the block. Install lower main bearing halves (4) in the main bearing cap.4. Put clean oil on the thrust bearing for the No. 5 main bearing. Install the thrust bearing with the identification "BLOCK SIDE" toward the cylinder block. When the bearing clearance is checked and the engine is in a vertical position, such as in the vehicle, the crankshaft will have to be lifted up and held against the upper halves of the main bearings to get a correct measurement with the Plastigage. The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, it is not necessary to hold the crankshaft up. Do not turn the crankshaft when the Plastigage is in position to check clearances. 5. Check the main bearing clearances with Plastigage (B) as follows: a) Put a piece of Plastigage (B) on the surface of the lower half of the main bearing.
Make sure part number on cap is toward front of engine and number on bottom of cap is the same as number on cap saddle when the caps are installed.
Do not turn the crankshaft when Plastigage (B) is in position.b) Install main bearing caps (1) for No. 1, 3 and 5 main bearings. Put clean engine oil on the bolt threads and the face of the washers and install the bolts. Tighten the bolts to a torque of 30 3 lb.ft. (40 4 N m).
Do not use an impact wrench to tighten the bolts the additional 90°.
c) Put a mark on each bolt and main bearing cap, then tighten the bolts 90° more.d) Remove the main bearing caps for No. 1, 3 and 5 main bearings. Remove Plastigage (B) and measure the width of the Plastigage. The main bearing clearance must be .0030 to .0065 in. (0.076 to 0.165 mm). Maximum permissible clearance with used bearings is .010 in. (0.25 mm).6. Install main bearing caps (1) and tighten the bolts as in Steps 5b and 5c.7. Remove No. 2 and 4 main bearing caps. Do Steps 2, 3, 5 and 6 for the No. 2 and 4 main bearings.
TYPICAL EXAMPLECheck the crankshaft end play with tooling (C). The end play is controlled by the thrust bearings on the No. 5 main bearing. End play with new bearings is .0025 to .0145 in. (0.064 to 0.368 mm). The maximum permissible end play with used bearings is .025 in. (0.64 mm).end by:a) install oil pan plateb) install oil pump