20459042 Volvo.Penta Pinion

At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. Remove the fill cap on the hydraulic oil tank only when the engine is stopped, and the fill cap is cool enough to touch with your bare hand.
1. Drain the hydraulic oil from the hydraulic oil tank. The capacity of the hydraulic oil tank is 72 liters (19 U.S. gal). 2. Remove the two nuts and bolts that fasten muffler (1) to the engine.3. Loosen bolt (3), and remove the clamp and muffler (2) from the engine.4. Loosen the two hose clamps, and remove hose (2) from the turbocharger and air cleaner housing. 5. Mark or identify all electrical wires for installation purposes. Slide the rubber cover down two electrical wires (6). Remove the nut, and disconnect the two electrical wires from the starter.6. Remove the plastic plug, and disconnect electrical wire (4) from the starter.7. Remove the bolt that fastens ground strap (5) to the flywheel housing.8. Disconnect hose assembly (7) from the primary fuel filter. Cap and plug immediately. Remove the bolt and clip that fastens hose assembly (7) to the flywheel housing. 10. Disconnect electrical wire (8) from the engine starting aid. Remove the four cable ties that fasten the electrical wire to the engine. 11. Mark or identify all electrical wires for installation purposes. Disconnect electrical wires (9) from the alternator.12. Remove the cable tie that fastens electrical harness (10) to the engine. 13. Disconnect electrical connector (12) from the hydraulic oil temperature switch.14. Disconnect electrical connector (16) from the engine coolant temperature switch.15. Disconnect electrical connector (17) from the engine oil pressure switch.16. Disconnect electrical connector (18) from the engine oil pressure switch.17. Mark or identify all electrical wires for installation purposes. Disconnect two electrical wires (13) from the fuel pump solenoid.18. Remove all of the cable ties that fasten electrical harness (10) to the engine. Move the electrical harness out of the way.19. Disconnect throttle cable (14) from the engine. Loosen jam nut (15), and remove throttle cable (14) from the bracket.20. Disconnect hose assembly (11) from the secondary fuel filter. Plug and cap immediately. 21. Disconnect hose assemblies (19) from steering pump (20). Disconnect hose assembly (21) from the hydraulic oil tank. Cap and plug immediately. 22. Disconnect hose assemblies (22) and (23) from the hydraulic oil cooler. Cap and plug immediately.23. Remove the two bolts that fasten plate (24) to the shroud and hydraulic oil cooler. Move the bracket and two hoses out of the way. 24. Mark or identify all electrical wires for installation purposes. Disconnect the two electrical wires from neutral start switch (25). Remove the cable ties that fasten the wiring harness to the pumps.25. Remove the cotter pin and pin that fastens control cable (27) to plate (28).26. Loosen jam nut (29), and remove control cable (27) from bracket (28). Move the control cable out of the way.27. Remove the two nuts and bolts, and remove plate (26) from the axle propel pump.28. Remove the two bolts, and remove bracket (28) from the axle propel pump. 29. Disconnect hose assemblies (31) and (32) from vibratory pump (30). Cap and plug immediately. 30. Disconnect hose assemblies (33) and (34) from axle propel pump (35). Cap and plug immediately. 31. Disconnect hose assemblies (36) and (37) from axle propel pump (35). Cap and plug immediately. 32. Disconnect hose assemblies (38) and (39) from the vibratory pump. Cap and plug immediately. 33. Disconnect the electrical connector for electrical connectors (40) from the main wiring harness. 34. Disconnect hose assemblies (41) and (42) from the axle propel pump. Cap and plug immediately. 35. Remove four bolts (44), and remove air cleaner housing (43) from the hydraulic oil tank. 36. Attach a hoist to engine (45) as shown. Remove four nuts and bolts (46) that hold the engine to the frame of the machine.37. Make sure all necessary hose assemblies and electrical wires have been disconnected. Carefully remove the engine, radiator, hydraulic oil cooler and pumps as a unit from the machine. The weight of the engine, radiator, hydraulic oil cooler and pumps as a unit is 704 kg (1550 lb). For installation of the engine, reverse the removal steps. After the engine has been installed, fill the cooling system with coolant to the correct level. Fill the hydraulic oil tank to the correct level. See the Operation & Maintenance Manual, Form No. KEBU6859, for the correct filling procedures.