22296415 Volvo.Penta Insert

Parts Needed
Engine Removal
Disconnect the cables to the batteries to prevent the possibility of personal injury and/or damage to electrical or electronic equipment. Refer to Service Manual for the engine removal information. The engine and torque converter may be removed as a unit if adequate lifting facilities exist.Approximate unit weights: Engine: 4364 kg (9600 lb). Torque converter: 567 kg (1,250 lb).It is not necessary to discharge refrigerant from the air-conditioning system when changing engines. Remove the condenser core and lines from the radiator guard and engine as a unit. Move core and lines to one side during the engine removal and reinstallation process. Engine mounted pumps may also be removed with hoses intact to minimize fluid loss and possible system contamination.Certain engine accessories may be reused if the accessories are serviceable. The condition of accessories should be evaluated prior to reinstalling them on the machine. Pay attention to the condition and cleanliness of any items being reused. Failure to replace unserviceable parts or adequately clean parts being reused will reduce the service life of the engine being installed. For reuse and inspection guidelines refer to Special Instruction, SEHS9634. Major items which may be reused if serviceable are:* Air inlet piping* Air cleaners (with new filter elements)* Exhaust piping* Starters* Fuel lines to engine* Special attachments installed on the engine* RadiatorInspect the frame and mounting locations for the engine supports and repair as necessary.Engine Installation
Before installing the engine, attach any component which may be difficult to attach later, such as the starter motors. Air cleaners and sensors for indicating air cleaner restriction, the sender for the coolant gauge, and engine mounted components of the starting aid system may also be installed at this time. (See the following topics and the wiring schematic for installation details and correct electrical connections.)If adequate facilities exist, install the engine and torque converter as an assembly into the machine's frame. Tighten engine support bolts to the specified torque. Reassemble radiator and guard, and reattach coolant and fuel lines. Install hydraulic pumps, lines, and other items such as drive shafts and guards which were removed earlier. Exhaust piping, hood and other engine attachments may also be reinstalled. (Do not reconnect the batteries at this time.)Engine Accessories and Engine Wiring
If you are installing a new or remanufactured engine from Caterpillar (with rear mounted alternator) the engine wiring harness will match the requirements of both the EUI engine and machine systems. Most electrical system connections to engine mounted devices will have already been made. Other connections must be made to both engine accessory and machine systems to ensure proper machine operation. When converting a machine from an MUI to EUI engine, it may be necessary to change wire terminal ends or connectors to adapt to another harness or device. If it is necessary to convert from one type of connector to another, use the correct size connector components and proper tools. Also ensure that wires are properly oriented within the connector. See the Reference Literature list for instructions and tools available for assembly of connectors.On a field converted engine with a front mounted alternator additional wiring to the alternator will be necessary. The information is covered in a separate topic.Starting Aid System
Illustration 1. 8E-8465 Starting Aid Group.
(A-A) Top View. (B-B) View from rear. (A) Turbo Outlet Adapter. (B) Left Side Guard. (C) Left Fender. (D) Turbo Shield. (E) Gear Housing.Install the engine mounted components of the starting aid group as shown in illustration 1. Items (B) and (C) may not be present if the group is being installed on an engine which has been removed from the machine.When installing the nozzle assemblies the indicator mark on the nozzle must be positioned to the top. Tighten each nozzle to a torque of 2.8 N m (25 lb in). Install the union (39) and place a cap over the open end to keep the system clean. The connection between the union and the ether valve assembly will be made later. See Illustration 1.Sensor and Mounting Group-Air Cleaner Restriction.
Illustration 2. 6I-4227 Sensor Group.
(F) Left Turbo Inlet Pressure Sensor. (G) Upper Water Regulator Housing. (H) Air Cleaner Supports. (I) Right Turbo Inlet Pressure Sensor. (AAA) Unused holes. Plug holes if present.Remove the air cleaner restriction indicators and tubes from air cleaner supports. The supports, if serviceable, may be reused, but the indicators and tubes will not be reused. Insert a new filter (4) into the threaded opening of each air cleaner support and then install a 9X-0263 Adapter (7) (1/8 npt thd) into the opening as necessary. Supports on early machines have only the 1/8 npt threaded opening. Plug holes at (AAA), if present, with a 9S-4182 Plug and 6V-5048 Seal (3). See Illustration 2.Place a 6V-5048 Seal (3) on each adapter. Attach a 6V-1926 Sensor Assembly (2). Connect the left sensor to harness with wire codes-D772-PU-16, 993-BR-16, and 997-OR-16). Connect the right sensor to the harness with wire codes-A980-BU-16, 993-BR-16, and 997-OR-16).Install a 4P-7581 Clip (1) and a 9X-3495 Clip Assembly (9) at locations shown in Illustration 2. Do not tighten the clips' mounting bolts at this time. (The orientation of the clips will vary with the type of air cleaner support used and some alignment of clips will be necessary.) Insert each sensor into a clip assembly so the electrical leads and engine wiring harness are not strained when the harness is positioned to be tie-strapped to a 4P-7581 Clip (1).Secure the wires with tie straps as shown in Illustration 2. Tighten the mounting bolts for the clips.Coolant Temperature Sender
Illustration 3. 6N-5926 Sender location.
(J) Coolant temperature switch. (K) Location of coolant temperature sender. (L) Ether enable temperature switch.Remove the 6T-6762 Plug from Location K in Illustration 3 on the cover at left end of the temperature regulator housing. Install a 6N-5926 Sender (82). Attach the engine harness (wire code-441-OR-16) to the sender. Secure the harness with a cable strap. See Illustration 3.Front Lights, Forward horn, and Dual Tilt
At the left, front of the engine, connect the engine harness (wire codes-200-BK-14,