21189037 Volvo.Penta Expansion plug

Table 1
Engine Arrangement
Original Engine Replacement Engine
7W-5178 110-7949
4N-2250
7N-2400
1W-6293 This Special Instruction does not include procedures that can be found in your existing manuals. Refer to the original Service Manual, Parts Manual, and Operation and Maintenance Manual for more information.When you have completed this procedure, prepare the machine for service. Refer to the Operation and Maintenance Manual.Note: Do not perform any procedure in this Special Instruction until the information has been read and understood.Reference: Service Manual, Parts Manual, Operation and Maintenance Manual.Note: This instruction contains some procedures that come from dealer feedback. If errors are found, submit feedback in SIS Web or contact the Emissions Retrofit Group.Safety
Personal injury or death can result from sudden machine movement.Sudden movement of the machine can cause injury to persons on or near the machine.To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.
Do not attempt to assemble this machine until you read and you understand the assembly instructions.Improper assembly procedures could result in injury or death.
Personal injury or death can result from improper lifting or blocking.When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component.Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Welding on Electronically Controlled Engines
Proper welding procedures are necessary in order to avoid damage to electronic controls. Perform welding on the engine according to the following procedure.
Set the engine control to the "STOP" mode.
Turn OFF the fuel supply to the engine.
Disconnect the negative terminal from the battery.
Disconnect the electronic components of the engine from the wiring harnesses: ECM, throttle actuator, actuator for the bypass of the turbocharger compressor, fuel metering valve and sensors.
Protect the wiring harnesses from welding debris and/or from welding spatter.
Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.
Connect the ground cable of the welder directly to the component that will be welded. Place the clamp as close as possible to the weld. This action will reduce the possibility of welding current damage to the engine bearings, to the electrical components, and to other engine components.
Use standard welding procedures to weld the materials together.Required Parts
Note: Fabricated parts are required. Refer to the procedure for details of the parts that are to be fabricated.Note: The parts in this instruction are for reference. The parts in the tables are from the dealer work order. The contents of the parts lists can vary. The condition of the machine will determine if more parts are required. If errors are found, submit feedback in SIS Web or contact the Emissions Retrofit Group.
Table 2
Parts for Air Inlet
Quantity Pt. No. Description
1 1W-2093 Tube
2 2M-5173 O-Ring Seal
1 4N-8089 Tube
1 5K-5068 Pipe Nipple
40 cm 5P-2817 Hose
6 5P-3860 Clamp
2 6N-1097 Hose
1 7M-1674 Screen
1 7X-0492 Elbow
1 8T-4128 Adapter