828592 Volvo.Penta Plastic plug

1. Check each bearing cap (1) for its location on the engine. Each cap has an arrow which is toward the front of the block and a number which gives the location of that cap. Keep each bearing with the correct cap.2. Remove bearing caps No. 2 through No. 6. Remove the thrust plates from No. 4 upper bearing.3. Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft as shown. Remove No. 1 and No. 7 main bearing caps. Remove the crankshaft. Weight of the crankshaft is 181 kg (400 lb.).
Be careful not to damage the crankshaft journals when the crankshaft is removed.
4. Remove crankshaft gear (2) with tooling (A).5. Remove the dowel and the pin from the crankshaft with tooling (B).6. If necessary, remove the plugs from the crankshaft.Install Crankshaft
1. If any of the plugs were removed, install them into the crankshaft to a minimum depth of 2.54 mm (.100 in.) and with a minimum torque of 23 N m (17 lb.ft.). Stake (make a mark with a punch) the crankshaft to hold the plug tight.2. Install pin (1) in the crankshaft end until it is extended from the surface to a maximum distance of 6.4 mm (.25 in.).3. Install dowel (2) until it is extended from the surface a distance of 4.1 0.5 mm (.16 .02 in.). 4. Heat crankshaft gear (3) to a maximum temperature of 233°C (451°F). Install gear (3) on the crankshaft with groove (4) in alignment with dowel (2).5. Make sure the upper main bearings are clean. Put clean oil on the upper main bearings and journals of the crankshaft. 6. Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft and put it in position on the block.
Use care to prevent damage to the crankshaft journals. Make sure the "V" mark on the crankshaft gear is in alignment with the "V" mark on the idler gear.
For more detail about installation of main bearings, see Remove And Install Crankshaft Main Bearings.7. Check the bearing clearances with Plastigage.
When Plastigage is used to check bearing clearances, do not use an impact wrench for the torque tightening sequence. However, an impact wrench can be used for the final tightening torque.
8. Put clean engine oil on the bolts for caps No. 1 and No. 7. Install No. 1 and No. 7 caps with the bolts finger tight. Make sure the arrows on the caps are toward the front of the block. 9. Install thrust plates (5) from the No. 4 upper main bearing. Install the thrust plates with the side that has identification "BLOCK SIDE" toward the cylinder block.10. Put clean oil on the bolts for caps No. 2 through No. 6. Install caps No. 2 through No. 6 with the bolts finger tight. Make sure the arrows are toward the front of the block.11. Tighten the cap bolts as follows:a. Tighten the bolts on the tab end of the caps first to a torque of 258 14 N m (190 10 lb.ft.).b. Tighten the bolts on the other end of the caps to a torque of 258 14 N m (190 10 lb.ft.).c. Put a mark across the bolt head and cap. Tighten the bolts opposite the tab end 120° 5° more. Tighten the bolts on the tab end of the cap 120° 5° more. 12. Check the end play of the crankshaft with tool (A). Make sure the dial indicator is against a machined surface. End play with new thrust plates must be 0.15 to 0.51 mm (.006 to .020 in.). The maximum end play with used thrust plates is 0.89 mm (.035 in.).END BY:a. install pistonsb. install flywheel housingc. install timing gear coverd. install oil pump