469207 Volvo.Penta Cover

Introduction
This Special Instruction provides instructions for relocating the engine air intake relay from the engine onto the frame. This new location saves the relay from exposure to engine vibration that could diminish the lifespan of the relay.Safety Section
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
Accidental engine starting can cause injury or death to personnel working on the equipment.To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system.Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.
Required Parts
Illustration 1 g06154382
Table 1
Parts List
Qty Part
1 090-8635 Spacer
4 101-9759 Spacer
2 208-9277 Bolt
1 231-0336 Taperlock Stud
2 353-7952 Grommet
1 398-0940 Magnetic Switch Gp
1 515-3177 Plate
1 515-3178 Plate
1 515-3182 Engine Harness As
2 5C-2890 Nut
2 6V-1889 Clip
2 6V-5839 Washer
2 6V-6317 Bolt
2 6V-8225 Nut
4 7K-1181 Cable Strap
1 8T-4121 Hard Washer
1 8T-4133 Nut
2 8T-4138 Bolt
4 8T-4224 Hard Washer
4 8T-6869 Bolt
1 9G-8451 Block
4 9X-8256 Washer
2 9X-8267 Washer Procedure
Illustration 2 g06154514
Remove 458-0320 Engine Harness As (1) and the remaining connectors from air intake magnetic switch (2). Remove the switch and mounting bracket (3). Both parts will not be reused.
Illustration 3 g06154516
(1) 458-0320 Engine Harness As
(4) 9G-8451 Block
(5) 515-3182 Engine Harness As
(6) 515-3177 Plate
(7) 6V-6317 Bolt
(8) 6V-5839 Washer
(9) 2-Pin Deutsch connector
(10) 8T-4138 Bolt
(11) 9X-8256 Washer
(12) 5C-2890 Nut
Position plate (6) on the engine and secure with two bolts (7) and washers (8).
Install block (4) onto the plate using two bolts (10), washers (11), and nuts (12).
Install the lugs of engine harness (1) and engine harness (5) onto the block. Attach 2-pin Deutsch connector (9) to the plate using a cable strap.
Remove the four bolts and washers that secure the ether mounting plate to the frame and set the assembly aside. Note that the same mounting bosses will be used to mount the assembly step 7.
Illustration 4 g06154558
(5) 515-3182 Engine Harness As
(13) 515-3178 Plate
(14) 208-9277 Bolt
(15) 9X-8267 Washer
(16) 6V-8225 Nut
(17) 7K-1181 Cable Strap
(18) Ether assembly
(19) 8T-6869 Bolt
(20) 8T-4224 Hard Washer
(21) 101-9759 Spacer
(22) 398-0940 Magnetic Switch Gp
Install magnetic switch (22) onto plate (13) using two bolts (14), washers (15), and nuts (16).
Mount the plate and ether assembly (18) to the frame using four bolts (19), washers (20), and spacers (21).
Attach engine harness (5) to the switch in four places as shown in Illustration 4. Secure the Deutsch connector and the main lugs to the plate using three cable straps (17).
Illustration 5 g06154565
(23) 6V-1889 Clip
(24) 353-7952 Grommet
(25) 231-0336 Taperlock Stud
(26) 8T-4121 Hard Washer
(27) 090-8635 Spacer
(28) 8T-4133 Nut
Secure the harness at two locations using clip (23) and grommet (24). Install stud (25), washer (26), spacer (27), and nut (28) onto the intake manifold to secure the harness to the engine. Attach ether hose clip (28) onto stud (25).