3801204 Volvo.Penta Starter motor, exch

Illustration 1 g01406987
Typical example
Front view of the engine
Note: The top face of the cylinder block, both sides of plate gasket (2) and bottom surface of spacer plate (1) must be free of fuel, oil, water, gasket adhesives, assembly compounds and any other contaminants during assembly. (3) Torque for three taperlock studs ... 27 4 N m (20 3 lb ft) (A) Thickness of the spacer plates ... 8.585 0.025 mm (0.3380 0.0010 inch) (B) Thickness of plate gasket that is between cylinder block and spacer plate ... 0.208 0.025 mm (0.0082 0.0010 inch) (C) Extension of the dowels on the left bank and right bank from the cylinder block ... 18.5 0.5 mm (0.73 0.02 inch)Note: Apply 5P-3413 Pipe Sealant on the threads of the taperlock plugs (4) before assembly. (4) Torque for the three taperlock plugs ... 80 15 N m (60 11 lb ft) (D) Bore in cylinder block for main bearing ... 129.891 0.013 mm (5.1138 0.0005 inch) (E) Dimensions for crankshaft bearing cap The width of the slot for the main bearing caps ... 215.900 0.013 mm (8.5000 0.0005 inch)Width of main bearing cap ... 215.900 0.025 mm (8.5000 0.0010 inch)
Illustration 2 g01406651
Right side view of the engine
(7) Apply 6V-6640 Sealant on the cup plug. (G) Extension of dowels from the rear face of the cylinder block and from the front face of the cylinder block ... 19.0 0.5 mm (0.75 0.02 inch)
Illustration 3 g01406653
Section F-F
(8) Oil jet tube assembly (9) Torque for the special bolts ... 25 7 N m (18 5 lb ft)Note: The main bearing caps (5) must be installed with the identifying marks toward the front of the engine. The number of the main bearing cap (5) must also match the cast number on the left side of each main bearing saddle.Use the following procedure to install the main bearing caps:
Illustration 4 g01407019
Marks for tightening main bearings
Apply clean engine oil on the threads of the main bearing cap bolts (6). Loosely install the main bearing cap bolts (6).
Tighten the main bearing cap bolts (6) first on the main bearing tab side of the main bearing cap (5) to 258 14 N m (190 10 lb ft).
Tighten the main bearing cap bolts (6) that are opposite the main bearing tab side of the main bearing cap (5) to 258 14 N m (190 10 lb ft).
Put a mark on each main bearing cap bolt (6) and each main bearing cap (5). See Illustration 4.
Tighten the main bearing cap bolts (6) that are placed opposite the main bearing tab side of the main bearing cap (5) from the mark by angle (H) of 120 5 degrees.
Tighten the main bearing cap bolts (6) that are placed on the main bearing tab side of the main bearing cap (5) from the mark by angle (H) of 120 5 degrees.
Illustration 5 g01406997 (J) Bores in the block for the camshaft sleeve bearings. ... 76.835 0.018 mm (3.0250 0.0007 inch) (K) The distance from the centerline of the crankshaft bearing bore to the top of the cylinder block ... 419.10 0.15 mm (16.500 0.006 inch)Minimum distance from the centerline of the crankshaft bearing bore to the top of the cylinder block (top deck) ... 418.67 mm (16.483 inch) (L) The distance from the centerline of the crankshaft bearing bore to the bottom of the cylinder block ... 165.10 0.10 mm (6.500 0.004 inch)