21675458 Volvo.Penta Common rail

Disconnect batteries prior to starting any portion of the engine removal.
start By:a. remove hoodb. raise cabc. remove crankcase guardd. remove air conditioning condensere. remove radiatorf. remove radiator supportg. remove coolant tankh. remove transmission oil cooler Prior to the removal of any wires, hoses or cables, insure that each is identified. Tape or cap the ends of hoses and fittings as they are disconnected. This will prevent debris from entering the system and prevent thread damage to each during removal and installation. 1. Disconnect two air conditioner compressor hoses (2).2. Remove plastic tie wraps from the hoses and lines on the top and the sides of the engine. This will allow the hoses, wires, and cables to be placed to the side of the engine compartment thus preventing damage to them during removal.3. Move the air conditioning dryer (4) to the side of the engine compartment.4. Disconnect and set aside heater hose (5) from the water pump.5. Set aside all of the hoses located on the top of the engine 6. Disconnect air conditioning electrical leads (6). Remove the clips that secure the wiring to the side of the block.7. Disconnect control cable for the fuel pump and governor (7). Disconnect the "U" bolt that holds the cable. 8. disconnect and label two electrical leads (8) on the solenoid shutoff. Remove the clips that secure the wiring to the side of the block.9. Disconnect and label all electrical disconnects from the engine. 10. Disconnect and plug fuel line (9). 11. Remove the bolts that secure bracket (10) to the engine. 12. Remove front motor mount bolts (11). 13. Disconnect the starting aid tube (15).14. Loosen two clamps and remove air intake tube (13).15. Remove four wires (12) connected to the starter. Remove the clips that secure the wiring to the side of the block.16. Disconnect two wires (14) from the back of the alternator. Remove the clips that secure the wiring to the side of the block. 17. Disconnect and remove wire leads (16) to the coolant sensor. 18. Disconnect coolant temperature wire (17) located on the thermostat 19. Disconnect and identify wire connections (18). Remove the clips that secure the wiring to the side of the block.20. Remove and plug three hydraulic hoses (19).21. Remove hydraulic cross-over check valve (20).22. Loosen the clamps from both ends of the exhaust flex-tube, and remove exhaust flex-tube (21). 23. Remove and plug hose (22). 24. Install tooling (A) under the torque converter housing and secure tooling (A) to it. This will support the torque converter housing and prevent any spline damage during engine removal. 25. Inspect all four sides of the engine and flywheel housing. Insure that there are no additional connected wires or hoses that have not been previously disconnected.26. Install chains and hoist to the front and rear lifting eyes of the engine as shown. Do not apply any tension to the chains at this time.27. Remove twelve bolts (26) that secure the retarder housing to the flywheel housing.28. Apply tension to the chains and hoist that hold the engine but do not lift it.29. Remove two rear engine support bolts (23), one from each side.30. Remove two rear engine support bolts (25), from both sides of the engine and remove two rear engine supports (24).31. Lift engine and flywheel housing slightly. Raise tooling (A) correspondingly to allow for the raise in the engine.32. Move the engine and flywheel housing forward slightly. The flywheel housing should separate from the retarder at this time. If they do not separate, place a pry bar between the two and gently pry apart.33. After the engine and flywheel housing separate, slowly raise the engine out and away from the truck frame. Weight of the engine and flywheel housing together is approximately 647 kg (1,424 lb). Continue to inspect to ensure that no hoses, or wires are still connected and that none have become snagged on the engine as it is being removed. For installation of the engine, reverse the removal steps. Insure that wires and hoses are connected in their proper location based on the identification marks placed on them during disassembly. Recheck all connections prior to reconnection of the batteries.34. Fill the radiator to the correct level.35. Fill the hydraulic oil tank to the correct level.End By:a. install transmission oil coolerb. install coolant tankc. install radiator supportd. install radiatore. install air conditioning condenserf. install crankcase guardg. lower cabh. install hood