21901745 Volvo.Penta Bracket

Start By:a. remove loader armb. remove tilt cylinderc. remove ROPSd. remove radiator and guarde. remove rear bottom guardf. remove floor plateg. remove air cleaner housingh. remove muffler Prior to the disconnection or removal of any wires, wiring harnesses, hoses or cables insure that all are clearly marked and identified. The particular machine displayed in this story was equipped with a ROPS and not a cab. Some models may be equipped with a cab. Those that are equipped with a cab may also be equipped with air conditioning. If this is the case, the engine removal will require a slightly different removal and installation procedure. The D4C engine removal and installation in this publication can be used as a model. 1. Disconnect battery. Remove two tie wraps (1) from wiring harness located at the left front side of the firewall. Identify and label five connectors (2) and disconnect. 2. Remove one bolt and washer (3) and remove ground wire terminal (4) from firewall. 3. Remove tie wraps (5) and disconnect wire connector (6) located under the dash on the left side. 4. Remove two tie wraps (7). Identify and label three wire connectors (8) and disconnect. Remove two tie wraps (9) from wiring harness clips (10). Wire connectors and tie wraps located under firewall at the rear of the engine. 5. identify and label wires at starter motor (14). Slide back terminal cover (15) and remove nut from positive battery cable and remove cable from starter motor (14). Raise cover at wire terminal (16) and remove screw and wire from starter motor (14). 6. Drain hydraulic fluid from the hydraulic tank. Disconnect hydraulic line (11) from implement pump (13). Plug and cap all fittings. 7. Shut off fuel supply at the fuel tank. Loosen clamp (17) on fuel line and remove fuel line from injection pump. Remove one bolt, washer and clip (18) that holds fuel lines.8. Loosen clamp (19) below priming pump and remove fuel line from priming pump. Plug all fuel lines. Set aside both fuel lines. 9. Remove cotter pin and pin (20) from governor control linkage.10. Loosen one jam nut (21) on cable bracket (22) and slide cable assembly out of bracket (22) and set cable assembly aside. 11. Remove three bolts, washers and clips (23) from the top of the transmission cover.12. Disconnect wire connector (24) and set aside.13. Disconnect and remove four steering-brake rods (25) from the pedal assembly (26). 14. Disconnect two hoses (27) at the rear of the transmission. 15. Remove four pins and washers (28) from pedal assembly (26). 16. Remove four bolts and washers (29) from two shaft cables (30). Remove both cable assembles and seals (30) from the rear of the transmission and set aside. 17. Remove two bolts (31) from flange to remove bracket (32).18. Remove one bolt, washer and clip (33) from bracket (32). At this time, remove hydraulic line (11) shown in step (6). 19. Loosen hose clamp (34). This hose is the lower hydraulic line to the implement pump. This line will stay with the engine and transmission when removed from the machine. 20. Remove two transmission cooler lines (35) from the left side of the transmission case. Plug and cap all fittings. 21. Attach tooling (A) as shown to engine lifting group. 22. Remove two bolts, washers and mount assemblies (36) from the transmission supports. 23. Remove two bolts, nuts, washers and mount assemblies (37) from the engine supports. The engine and transmission must be at the approximate angle shown below to have clearance for the transmission to clear the opening in the firewall. 24. Using tooling (A) remove the engine and transmission slowly from the machine. Check carefully to see if all hoses, wires and tubes are completely disconnected and free of the engine and transmission prior to removal.25. Gradually shift the weight of the engine and transmission by adjusting tooling (A) to achieve the correct angle for removal. The weight of the engine and transmission is 806 kg (1,775 lb). Use the following procedure for installation of the engine and transmission. The particular machine displayed in this story was equipped with a ROPS and not a cab. Some models may be equipped with a cab. Those that are equipped with a cab may also be equipped with air conditioning. If this is the case, the engine removal will require a slightly different removal and installation procedure. The D4C engine removal and installation in this publication can be used as a model. 26. Position mount assembly with sleeves in place as shown prior to installing engine and transmission.27. Using tooling (A), install engine and transmission. Starting at the approximate angle and returning to horizontal as the engine and transmission enters through the opening in the firewall. 28. Install two mount assemblies (37) to engine supports. 29. Install hydraulic jack under the transmission and lift the transmission high enough to install transmission mount assembly (36). 30. Remove tooling (A) from the engine lifting group. 31. Install two transmission cooler lines (35). 32. Install hydraulic hose and tighten clamp (34). Tighten to a torque of 4.5 .5 N m (40 5 lb in). 33. Install hydraulic lines bracket (32) with bolts (31). Install bolt, washer and clip (33) on hydraulic line (11). 34. Inspect and replace if necessary, O-ring seal on transmission shaft cable assembly (30). Install both transmission shift cable assembly (30) with bolts and washers (29). 35. Install four pins and washers (28) into pedal assemble (26). 36. Install two hose fittings (27) at the rear of the transmission. 37. Install four steering-brake rods (25) from valves to pedal assembly (26).38. Connect wire connector (24). Install three bolts, washers and clips (23) to the top of the transmission cover. 39. Install governor cable assembly on bracket (22). Tighten nut (21) to 38 2 N m (28 1 lb ft). Install pin and cotter pin (20) to injection pump linkage. 40. Install two fuel lines and tighten clamps (17)