20930510 Volvo.Penta Oil separator

START BY:a) remove radiator and guard 1. Remove crankcase guard and drain the hydraulic tank.2. Remove precleaner group (1) from the air cleaner. Remove panel assemblies (2) and (3). The weight of panel assembly (2) is 34 kg (75 lb.). 3. Remove the wiring harness from frame assembly (6). Remove the bolts that fasten frame assembly (6) to frame assemblies (4) and (5). Remove frame assembly (6). Weight of frame assembly is 29 kg (65 lb.). 4. Remove two bolts (7) and covers from the rear fenders. Disconnect governor cable assembly from panel assembly. Remove panel assembly from between the fenders. The weight of the panel assembly is 48 kg (105 lb.). 5. Remove the wiring harness from channel assembly (8). Remove channel assembly (8) from vehicle. 6. Disconnect wiring harness (9) from the filter base. Remove filter housing (10) and (11) and hose assemblies from the support assembly. 7. Remove bracket (12) from the fuel filter. 8. Open the right hand panel door and disconnect two electrical plugs (13) from the relay panel. 9. Loosen clamp and slide hose from the turbocharger elbow. Remove dust ejector tube (15) from the muffler.10. Install straps on the filter support (14). Remove mounting bolts from the side panels and remove filter support, air cleaner and relay panel as a unit. Weight of the assembly is 77 kg (170 lb.). 11. Put identification on fuel hoses for installation purposes. Disconnect hoses (16) and (17) from tube assemblies. 12. Disconnect fuel tube assembly (18) from fuel filter and tube assembly (19) from fitting. 13. Remove doors and install strap on frame assembly. Remove mounting bolts and frame assembly (20). Weight of the frame assembly is 39 kg (85 lb.). 14. Disconnect wiring harness (22) and ether tube assembly (21). 15. Remove doors and install strap on frame assembly. Remove mounting bolts and frame assembly (23). Weight of the frame assembly is 39 kg (85 lb.). 16. Loosen hose clamps (25) and slide hose (26) from tube assembly. Remove tube assembly (24) from the steering pump.17. Remove tube assembly (27) from the hydraulic pump. Loosen the hose clamp at opposite end of tube assembly (27) and move it to the side of the vehicle. 18. Put identification on hose assemblies for installation purposes. Disconnect four hose assemblies (29). Disconnect tube assembly (28) from the transmission pump. Loosen hose clamp on the opposite end of tube assembly (28). 19. Remove driveshaft (31) and disconnect tube assembly (30). 20. Disconnect electrical plugs (32) and (33). 21. Put identification on and disconnect necessary wires (34) from the electric starting motor.
Always wear goggles when the air conditioning system is opened. This system is charged with Freon-12 (CCL2F2 Dichlorodifluoromethane) which is not toxic or flammable. There is however, reason for caution. When Freon-12 makes contact with a flame, lethal phosgene gas is made. INHALING FREON THROUGH A LIGHTED CIGARETTE CAN CAUSE VIOLENT ILLNESS. This system is under pressure at all times, engine running or not. HEAT MUST NEVER BE APPLIED TO A CHARGED SYSTEM. See Air Conditioning And Heating Service Manual Form No. SENR7454 for more information on procedures and safety requirements on removal and installation of lines and refrigerant from the system.
22. Put identification on wires (35) and hose assemblies (36) and (37) for installation purposes. Disconnect wires and hose assemblies from the air conditioning compressor. 23. Loosen hose clamp (38) and slide tube assembly (40) from hose. Disconnect hose assembly (39) from the transmission oil cooler bonnet fitting. 24. Loosen clamps and remove hoses (41) and (42) from valves. Disconnect hose clamp (43). 25. Remove cotter pin and pin (45) from control lever and the cable assembly. Move the governor control cable (44) to the side of the engine compartment. 26. Install a hoist on the muffler and remove mounting bolts and muffler (47) and elbow (46) from the engine. 27. Disconnect hose assembly (48) from the torque converter. 28. Remove clamp (50) and clip (51). Remove tube assembly (49) from the transmission oil cooler.29. Install tooling (A) on engine as shown in photo B69550X1. The link bracket is installed at the starter location on the left side of the engine. A nylon strap is installed through the turbocharger so no force is placed on the turbocharger cartridge. 30. Remove four bolts (52) that fasten engine support to the frame. 31. Remove two bolts (53) and cap (54) from each side of the engine.
Use care not to put an overload on the ratchet hoist when the engine and torque converter are removed.
32. Remove engine (55) from the vehicle with tooling (A). Weight of the engine is 2495 kg (5500 lb.).Install Engine And Torque Converter
1. If necessary, make a replacement of the rear engine supports as follows:a) Remove mount assembly (1) from support (2).b) Install new mount assembly (1) on support (2) until the inner cup is tight against shoulder of the pin.c) Make sure support (2) is installed with a minimum of distance from the mount assemblies to the rear face of the cylinder block. Make sure the alignment of the pipe assembly from the hydraulic pumps to the hydraulic supply line is correct before the engine is lowered on its mounts.
Use care not to put an overload on the ratchet hoist [part of tooling (A)] when the engine and torque converter are installed.
2. Fasten a hoist to the engine with tooling (A) and put the engine and torque converter in position in the machine. 3. Install the four bolts (3) that fasten the engine front support to the frame. 4. Install caps (4) and bolts on each side of the engine. 5. Inspect seal and make a replacement if necessary. Install seal and tube assembly (5) on the transmission oil cooler. Install clamp (6) and clip (7). 6. Conn