3825235 Volvo.Penta Valve

START BY: a. remove oil pan1. Put the engine on tooling (A). 2. Remove the bolts that hold main bearing cap (1). Remove main bearing cap (1) and the lower half of the main bearing.3. Remove the bearing from the cap.
If the crankshaft is turned in the wrong direction, the tab of the bearing will be pushed between the crankshaft and cylinder block. This can cause damage to either or both.
The center and two end main journals have no oil hole. To remove these bearings, put a thin piece of soft material that will not damage the crankshaft journal against the end of the bearing opposite the tab. Hit the bearing with the soft material until the tab of the bearing is free from the groove in the cylinder block. Remove the upper half of the main bearing.4. Remove the upper half of the other main bearings as follows: a. Turn the crankshaft until tool (B) can be installed in the crankshaft journal. Install tool (B).b. Turn the crankshaft in the direction which will push the upper main bearing out, tab end first.c. Check the condition of the bearings. (See Guideline For Reusable Parts, Main And Connecting Rod Bearings, Form No. SEBF8009.) 5. Remove crankshaft thrust bearings (2) from each side of the No. 3 main bearing saddle. Install the main bearings dry when the clearance checks are made. Put clean engine oil on the main bearings for final assembly. Also, be sure the tabs on the back side of the main bearings fit in the grooves of the main bearing caps and cylinder block.6. Clean the surfaces in the cylinder block for the main bearings. Use tool (B), and install new upper halves of main bearings (bearings with the oil hole) in the cylinder block. Do not put oil on the bearing.7. Clean the surfaces of the main bearing caps for the main bearings. Install the new lower halves of the main bearings in the main caps without oil.
Typical ExampleThe 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 not 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. SEBD0531.8. Check the main bearing clearance with Plastigage (C) as follows: a. Put a piece of Plastigage (C) on the crown of the bearing half that is in the cap or on the crankshaft journal as shown.
Make sure the part number on the main bearing caps is toward the front of the engine and the number on the main bearing caps is the same as the number on the outside (camshaft side) of the cylinder block.
b. Put main bearing caps (1) in position on the cylinder block. Put 2P2506 Thread Lubricant on the bolt threads and the contact surfaces of the bolt heads, and install the bolts. Tighten the bolts on the side where the main bearing tabs are located to a torque of 61 6 N m (45 4 lb.ft.). Tighten the bolts on the opposite side to a torque of 61 6 N m (45 4 lb.ft.).c. Put a mark on each bolt head and the bearing caps. Turn the bolts that are opposite the main bearing tabs an extra 60° 5° from the mark. Turn the bolts on the side where the main bearing tabs are located an extra 60° 5° from the mark.d. Remove main bearing caps (1), and measure the Plastigage. This will determine the bearing clearance. The main bearing clearance with a new bearing must be 0.076 to 0.168 mm (.0030 to .0066 in.). The maximum permissible clearance with used main bearings is 0.18 mm (.007 in.). 9. Put clean engine oil on thrust bearings (2) from the No. 3 main bearing saddle. Install a thrust bearing on each side of No. 3 main bearing saddle with the identification "BLOCK SIDE" toward the bearing saddle and the side with the oil grooves toward the crankshaft.10. Install main bearing caps (1), and tighten the bolts as in Steps 8b and 8c. 11. Check the end play of the crankshaft with tool (D). Be sure the dial indicator is against a machined surface. The end play is controlled by the thrust bearings on each side of No. 3 center main bearing. The end play with new bearings must