21344665 Volvo.Penta Valve guide

Table 1
Required Tools
Tool Part Number Part Description Qty
A 198-9113 Seal Installer 1
B 8T-9022 Silicon Gasket -
C 8H-8581 Feeler Gauge 1
D 8T-3052 Degree Wheel 1
Ensure that all of the lubrication passages are clean and free of debris.
Clean the seat for the main bearing in the cylinder block and clean the upper main bearings.
Illustration 1 g00985927
Install upper main bearings (9) with the bearing tabs in the correct position in the cylinder block. Lubricate upper main bearings (9) with clean engine oil.
Clean upper thrust washers and lubricate upper thrust washers (10). Place upper thrust washers (10) in the cylinder block on both sides of the number four crankshaft journal. The grooves on the thrust washer must be located against the crankshaft.
Illustration 2 g00985931
Ensure that the main bearing journals of crankshaft (8) are clean. Attach lifting straps and a suitable lifting device in order to position the crankshaft in the cylinder block.
Clean the lower main bearings. Install the lower main bearings in the main bearing caps with the bearing tabs in the correct position. Lubricate the lower main bearings with clean engine oil.
Clean the lower thrust washers and lubricate the lower thrust washers. Place the lower thrust washers in both sides of the number four main bearing cap. The grooves on the thrust washer must be located against the crankshaft.
Illustration 3 g00985933
Ensure that the dowels for main bearing caps (5) are in the correct position in the main bearing caps or in the cylinder block. Install main bearing caps (5) in the position that is marked during the removal process. All of the bearing tabs on the main bearings should be on the same side.
Install bolts (4) in the main bearing caps. Tighten the bolts to a torque of 147 N m (108 lb ft).
Illustration 4 g00740436
Position the front main bearing cap and the rear main bearing cap on the cylinder block. Install the seals in the front and the rear main bearing cap. Note: The seals for the front main bearing cap and for the rear main bearing caps have a curve at one end. The curved side must be installed toward the side of the engine. The curved end is inserted first into the hole.Note: Before installing the seals, inject a small quantity of Tooling (B) in the holes for the seals.
Illustration 5 g00740478
Start the seals into the holes by hand. Use Tooling (A) to push the seal into position. Use a small punch to push the seal below the surface of the main bearing cap until resistance is felt. Remove excess sealant from the holes. Note: The seals have a soft metal insert. Do not bend the seal when the seal is first inserted into the hole.
Illustration 6 g00740463Note: Before the front bearing cap and the rear bearing cap are fully tightened, use a straight edge to align the bearing cap with the face of the cylinder block.
Install the bolts for the front main bearing cap and for the rear main bearing cap. Tighten the bolts to a torque of 147 N m (108 lb ft). Note: Remove excess sealant from the recess of the rear oil seal. If this is not done, the rear oil seal will not fit properly.
Rotate the crankshaft in order to ensure that the crankshaft turns freely.
Illustration 7 g00986976
Check the crankshaft end play. Use a prybar to move the crankshaft toward the front of the engine. Use Tooling (C) to measure the end play between the rear thrust washer and the crankshaft. The maximum permissible crankshaft end play is 0.405 mm (0.0159 inch). Note: In order to install the serrated connecting rod caps, refer to Step 15. In order to install the fractured connecting rod caps, refer to Step 16.
Carefully push the piston and the connecting rod assembly onto the connecting rod journal. Remove the rubber hose from the connecting rod bolts. Put the serrated connecting rod cap (7) in position on the crankshaft. Install nuts (6). Tighten the nuts to a torque of 54 N m (40 lb ft).
Carefully push the piston and the connecting rod assembly onto the connecting rod journal. Put the fractured connecting rod cap (7) in position on the crankshaft and install new bolts (6) that fasten the connecting rod cap to the connecting rod. Tighten the connecting rod cap bolts to a torque of 48 N m (35 lb ft). Use Tooling (D) to achieve the correct final torque. Turn the bolts for an additional 90 degrees. Note: Do Not reuse the old bolts in order to secure the connecting rod cap.Note: If Tooling (D) is not used, place an index mark on each bolt.
Rotate the crankshaft in order to ensure that the crankshaft turns freely.
Illustration 8 g00699985
Position oil suction tube (2) on t