192426 Volvo.Penta Expansion plug

1. Disconnect three lines (1) going to the air dryer. Remove the air dryer. 2. Remove bolt and washer (2) and the clips holding the cables.3. Disconnect ground wire (3) from the starter. Disconnect the two red cables from the starter solenoid. 4. Remove two bolts and washers (5) and fitting (4) from the flywheel housing. 5. Disconnect three wires (6) from the sensors. 6. Disconnect line (8) from transmission oil cooler (7). 7. Disconnect line (9) and (12). Remove four bolts and washers holding housing (10) and (11) to the retarder housing. Remove the housings with the lines attached. 8. Loosen two clamps (13) and move boot (14) as far back as it will go.9. Remove three bolts and washers (15) and move retarder valve group (16) away from the retarder. 10. Remove bolt and washer (17) to free the hose assembly. 11. Loose clamp (18) and remove tube (19). 12. Disconnect hose assembly (20). Remove bolt and washer (21). Remove two bolts, washers and nuts (22). Move hose assembly (20) to the engine and secure. 13. Disconnect two fuel lines (23) and (24). 14. Disconnect tube assembly (25) from the air breather housing. 15. Remove two bolts and washers (26) and disconnect tube assembly (27). 16. Remove bolt, washer and clamp (28).17. Disconnect two hose assemblies (29) and (30). 18. Disconnect two tube assemblies (31) from transmission oil cooler (32). Remove the tube assemblies. 19. Disconnect hose assembly (33). Disconnect wire harness (34). 20. Remove four bolts and washers (36) and tube assembly (35) for access to lifting eye. 21. Remove air cleaner housing (37) for access to lines below air cleaner housing. Remove two bolts and washers holding brace (38) at the bottom. Remove the brace for clearance to remove the engine. 22. Disconnect two lines (39) and (40) from the retarder housing. 23. Disconnect hose assembly (41) and move out of the way. 24. Disconnect fuel line (42) and secure to the engine. 25. Disconnect two lines (43) and (44) from the air condition compressor. 26. Remove three bolts (45) and plate (46). 27. Remove two bolts and washers (47) and plate (48). 28. Remove spiral retaining ring (49).29. Re-install one of the bolts (47) loosely and use if to pull the drive shaft back by hand. Pull the drive shaft back and out of the retarder to provide clearance to remove the engine. 30. Attach Tooling (A) as shown. 31. Turn valves to the OFF position. Loosen the clamps and remove hoses (50) and (51). 32. Remove two bolts and washers (52).33. Disconnect the throttle linkage and the air line to the slave valve (not shown). 34. Remove two bolts and washers (54) and cap (53) from each side. The weight of the engine is 1816 kg (4000 lb). The Following steps are for the installation of the engine. 35. Install two bolts and washers (54) and cap (53) on each side. The weight of the engine is 1816 kg (4000 lb). Torque for bolts (54) to 240 40 N m (175 30 lb ft). 36. Install two bolts and washers (52).37. Connect the throttle linkage and the air line to the slave valve (not shown). 38. Turn valves to the ON position. Loosen the clamps and install hoses (50) and (51). 39. Attach Tooling (A) as shown. 40. Install spiral retaining ring (49).41. Re-install one of the bolts (47) loosely and use if to pull the drive shaft back by hand. Pull the drive shaft back and out of the retarder to provide clearance to remove the engine. 42. Install two bolts and washers (47) and plate (48). 43. Install three bolts (45) and plate (46). 44. Connect two lines (43) and (44) on the air condition compressor. 45. Connect fuel line (42). 46. Connect hose assembly (41). 47. Connect two lines (39) and (40) on the retarder housing. 48. Install air cleaner housing (37) after the lines below air cleaner housing are connected. Install two bolts and washers holding brace (38) at the bottom. 49. Install four bolts and washers (36) and tube assembly (35). 50. Connect hose assembly (33). Connect wire harness (34). 51. Connect two tube assemblies (31) on transmission oil cooler (32). Install the tube assemblies. 52. Install bolt, washer and clamp (28).53. Connect two hose assemblies (29) and (30). 54. Install two bolts and washers (26) and connect tube assembly (27). 55. Connect tube assembly (25) on the air breather housing. 56. Connect two fuel lines (23) and (24). 57. Connect hose assembly (20). Install bolt and washer (21). Install two bolts, washers and nuts (22). 58. Install tube (19) and tighten clamp (18). 59. Install bolt and washer (17). 60. Install boot (14) as far as it will go and tighten two clamps (13).61. Install three bolts and washers (15) and retarder valve group (16). 62. Connect line (9) and (12). Install four bolts and washers holding housing (10) and (11) to the retarder housing. 63. Connect line (8) to transmission oil cooler (7). 64. Connect three wires (6) to the sensors. 65. Install two bolts and washers (5) and fitting (4) t