1505359 Volvo.Penta Rotor kit

1. Put the engine in position on tool (A) as shown.2. Remove all main bearing caps except No. 4 main bearing cap. Install split pieces of rubber hose (1) over the studs to prevent damage to the crankshaft journals. 3. Install tool (B) on each end of the crankshaft. Fasten a hoist to the crankshaft.4. Remove No. 4 main bearing cap. Remove crankshaft (2). Weight of the crankshaft is 550 lb. (250 kg). 5. Remove upper halves (3) of the main bearings from the cylinder block.6. Remove lower halves of the main bearings from the main bearing caps.
Put identification on the bearings to prevent mixing when the crankshaft is installed in the cylinder block.
Install Crankshaft
1. Install main bearings (1) in the cylinder block. Make sure the bearings are in the correct position. 2. One gear tooth (3) on the crankshaft has a mark on it. The mark is on the chamfered end of the tooth next to the thrower. Put a mark across the top of the tooth with the mark of identification. Put a mark on the two teeth of the accessory drive gear (4) that has an "F" mark between them.3. Install tool (A) on the crankshaft (2). Fasten a hoist to the crankshaft and put it in position in the cylinder block. Install No. 4 main bearing cap to hold it temporarily.4. Turn the crankshaft and check to see that the gears that have the marks on them engage correctly. If gear teeth (3) and (5) do not engage correctly, remove the crankshaft (2). Turn the accessory drive gear (4) until gear teeth (3) and (5) engage with each other when the crankshaft is installed.5. Use wire (B) to check the bearing clearance. Put wire (B) on the bearing as shown. 6. Install main bearing cap (6) and tighten the nuts to a torque of 140 5 lb.ft. (190 7 N m). Put a mark on the caps and nuts. Tighten the nuts an extra 120° 5°. Remove the main bearing cap and check the thickness of the wire to find the bearing clearance. The bearing clearance must be .0040 to .0082 in. (0.102 to 0.208 mm) with new parts. Maximum permissible clearance with use parts must not be more than .012 in. (0.30 mm).7. Put clean engine oil on the threads of the studs and the seat for the nuts. Install the main bearing caps and tighten the nuts to a torque of 140 5 lb.ft. (189.8 6.8 N m). Put a mark on the caps and nuts. Tighten the nuts 120° 5° more from the marks. 8. Use tool (C) to check the end play of the crankshaft as controlled by the lower half of the center main bearing. The end play must be .012 to .023 in. (0.30 to 0.58 mm). 9. Turn the crankshaft until timing marks (10) on the accessory drive gear are in alignment with edge of oil thrower (9). Remove idler gear (8). 10. Turn camshaft until "V" mark on gear (11) is in alignment with the bolt hole in the timing gear housing assembly. Install bolt (12) between the gear teeth as shown. 11. Turn the camshaft in the fuel injection pump housing until timing pin (13) can be installed in the camshaft. 12. After the bolt is in position in the camshaft gear and the timing pin is in position in the camshaft of the fuel injection pump housing, make sure all of the timing marks are in alignment with each other. Install idler gear (14).end by: a) install flywheel housingb) install crankshaft front sealc) install oil pump drived) install pistonse) install governorf) install transmission magnetic screen *g) install transmission oil filter *h) install transmission oil cooleri) install torque converter *j) install engine*These operations are in the POWER TRAIN DISASSEMBLY AND ASSEMBLY SECTION.