842743 Volvo.Penta Tube

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. 4. Remove thrust plates from No. 3 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. 5 main bearing caps. Remove the crankshaft. Weight of the crankshaft is 122 kg (270 lb.).
Be careful not to cause damage to the crankshaft journals when the crankshaft is removed.
4. Remove crankshaft gear (2) with tooling (A).5. Remove dowel and pin from crankshaft with tooling (B).Install Crankshaft
If the crankshaft journals and bores for the block and rods were measured at disassembly and found to be within specifications, no further checks are necessary. However, if the serviceman still wants to measure the bearing clearances, Plastigage is recommended. Lead wire, shim stock or use of a dial bore gauge can damage the bearing surface.The serviceman must be very careful to use Plastigage correctly. The following points must be remembered:... Make sure that the backs of the bearings and the bores are clean and dry.... Make sure that the bearing locking tabs are properly seated in their slots.... The crankshaft must be free of oil where the Plastigage touches it.... If the main bearing clearances are checked with the engine upright or on its side, the crankshaft must be supported. Use a jack under an adjacent crankshaft counterweight, and hold the crankshaft against the crown of the bearing. If the crankshaft is not supported, the weight of the crankshaft will cause incorrect readings.... Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing.... Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful no to dislodge the bearing when the cap is installed.... Do not turn the crankshaft with the Plastigage installed. ... Carefully remove the cap, but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements.... Remove the Plastigage before installing the cap.When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004") the readings may be low by 0.013 to 0.025 mm (.0005 to .0010"). Out-of-round journals can give faulty readings. Also, journal taper may be indicated when one end of the Plastigage is wider than the other.For complete details concerning measuring bearing clearances, see Engine Bearings And Crankshafts, Form No. SEBD0531. 1. Install pin (1) in the crankshaft end until it is extended from the surface 6.4 0.5 mm (.25 .02 in.).2. Install dowel (2) until it is extended from the surface 4.1 0.5 mm (.16 .02 in.). 3. Heat crankshaft gear (3) to a maximum temperature of 204°C (400°F). Install gear (3) on the crankshaft with groove (4) in alignment with dowel (2). 4. Make sure the upper main bearings are clean. Put clean oil on the upper main bearings and journals of the crankshaft.5. Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft, and put it in position in the block.
Do not cause 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.6. Check the bearing clearances with tool (B).7. Put 2P2506 Thread Lubricant on the bolts for caps No. 1 and No. 5. Install No. 1 and No. 5 caps with the bolts finger tight. Make sure the arrows on the caps are toward the front of the block. 8. Install thrust plates (5) for the No. 3 upper main bearing. Install the thrust plates with the side that has the identification "BLOCK SIDE" toward the cylinder block.9. Put clean oil on the bolts for caps No. 2 through No. 4. Install caps No. 2 through No. 4 with the bolts finger tight. Make sure the arrows are toward the front of the block.10. Tighten the cap bolts as follows:a. Tighten the bolts on the tab end of the caps first to a torque of 260 14 N m (190 10 lb.ft.).b. Tighten the bols on the other end of the caps to a torque of 260 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°. Tighten the bolts on the tab end of the cap 120 . 11. Check the end play of the crankshaft with tool (A). Make sure the dial indicator is against a machined surface. End play for 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