Crankshaft & Main Bearings

NOTE: Oil pan may also be referred to as oil sump.

Remove engine from vehicle. See ENGINE under REMOVAL & INSTALLATION . Remove cylinder head. See CYLINDER HEAD under REMOVAL & INSTALLATION .
Place engine upside down. Remove oil filter. Disconnect flame trap return line. Remove oil pan. Remove all oil passage "O" rings. See Figure. Remove oil pump suction pipe and "O" ring.
Rotate crankshaft so all piston connecting rod bolts are accessible for removal without rotating crankshaft again. Starting at sides and working toward center, remove intermediate section bolts. Loosen intermediate section by carefully tapping with a plastic mallet. Remove crankshaft rear seal.
CAUTION: DO NOT allow crankshaft to rotate.
Check identification markings on connecting rods and connecting rod caps. Mark components for reassembly reference as necessary. Remove connecting rod caps. Lift crankshaft out of block and support on "V" blocks on 2 outermost main journals. Remove main bearings from block. Mark position of thrust bearing for reassembly reference.
Use micrometer and measure crankshaft out-of-round and taper. See Fig 1 and Fig 2 . Ensure to measure at several points around circumference and along length. Use Dial Gauge (9684) and Magnetic Stand (9696) to check straightness of crankshaft. See Fig 3. See ENGINE SPECIFICATIONS - 2.3L & 2.4L, 5-CYLINDER article.

Fig 1: Measuring Crankshaft Bearing Journal
Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 2: Identifying Bearing Journal Taper & Out Of Round
Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 3: Checking Crankshaft Runout
Courtesy of VOLVO CARS OF NORTH AMERICA.
Check the classification of the block and crankshaft. The classification marking is at the rear edge of the block and the crankshaft. See Fig 4. The classification is read from digits 1 to 7. The first letter after digit 1 is the classification of main bearing No. 1. The bearing positions are numbered starting at the front of the engine.

Fig 4: Locating Crankshaft & Engine Block Markings
Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE: The thickest of the bearing caps must always be installed in the intermediate section. This is to keep the center line as straight as possible.

Fig 5: Crankshaft Main Bearing Identification Table

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install the main bearings in the cylinder block and the intermediate section. See Fig 5. The axial bearing is positioned at bearing recess 5. For example: the marking on the block at bearing recess 1 is "B". The marking on the crankshaft at the corresponding bearing recess is "C". Therefore the bearing in the block is marked red and the bearing in the intermediate section is marked yellow.
Wipe the surfaces dry. Apply Liquid Gasket (11 61 059) to the intermediate sectionusing a roller. The surface must be completely covered without any excess. Thoroughly lubricate all the bearing shells and the surface of the axial bearing.
Install the two old bolts for the flywheel and carrier plate at the rear edge of the crankshaft. Lift these and the front of the crankshaft. Carefully position the crankshaft in the block. The crankshaft must NOT be turned before the intermediate section has been tightened. Position the intermediate section. Install all bolts. Use NEW 10-mm bolts. Draw the intermediate section down towards the block. Tighten the bolts in correct order to specified torque. See Fig 6. See ENGINE SPECIFICATIONS - 2.3L & 2.4L, 5-CYLINDER article.

Fig 6: Identifying Intermediate Section Bolts

Courtesy of VOLVO CARS OF NORTH AMERICA.