21859066 Volvo.Penta Pipe

1. Remove eight bolts (2) that hold the two tube assemblies to the bottom of the transmission oil cooler.2. Disconnect wire harness (3).3. Remove bracket (1) from the transmission oil cooler. 4. Close the two valves for the cab heater hoses. Disconnect two hoses (5). Remove all clips that hold the heater hoses to the side of the engine.5. Disconnect three hoses (4) at the air compressor. 6. Disconnect wiring harness (6) at the rear of the engine. 7. Disconnect tube assemblies (9) and (10).8. Remove two bolts (8) and the retainers. Loosen clamp (7). Remove four bolts (11) and two bolts (12) and the washers. 9. Fasten a lifting sling and a hoist to elbow (13). Remove the elbow from the rear of the engine. The weight of the elbow is 36 kg (80 lb). 10. Put identification marks on two wiring harnesses (14). Disconnect the wiring harnesses. 11. Remove cover (15) from the fuel system. 12. Remove bolts (16) and the washers that hold the control cable housing to the side of the governor. Remove the housing from the governor. 13. Disconnect tube assembly (20) from the fuel filter housing.14. Disconnect tube assembly (21) from the fuel system.15. Put identification marks on all wires that are connected to electric starting motor (18). Disconnect three wires (17) from the solenoid. Disconnect wire (19) from the electric starting motor. 16. Disconnect four grease tubes (25). Disconnect wire cable (23).17. Put identification marks on the wires that are connect to the disconnect switch. Remove wires (26) from the disconnect switch.18. Remove the bolts, washers and spacers that hold disconnect switch (24) to the frame of the machine. Remove the disconnect switch.19. Remove front engine mounting bolts (22). 20. Put a suitable floor jack (28) in position under the transmission so it will not fall when the engine is removed. Put slight lifting tension on the transmission. 21. Fasten tool (A) and a hoist to the engine lifting brackets. Put slight lifting tension on the engine. 22. Remove twelve bolts (29) and the washers that hold the torque converter housing to the flywheel housing. If necessary, use forcing screws to separate to the torque converter housing from the flywheel housing.23. Lift up on the engine a small amount, and remove it from the machine. The weight of the engine is 1089 kg (2400 lb).24. Remove the o-ring seal from the outside diameter of the torque converter housing. 25. Put spacer blocks (30) between torque converter housing (31) and the front support of the rear axle. The following steps are for the installation of the engine.26. Check the condition of the o-ring seal used on the outside diameter of the torque converter housing. If the seal is worn or damaged, use a new part for replacement.27. Install the o-ring seal on the torque converter housing, and put clean oil on it.28. Check the condition of the front engine mount assemblies. If the mount assemblies are worn or damaged, use new parts for replacement.29. Install the front mount assemblies in the front engine mounting brackets. 30. Fasten tool (A) and a hoist to the engine. Prior to installing the engine in the machine, be sure it hangs level.31. Install the engine in the machine, aligning the flywheel with the torque converter. 32. Install twelve bolts (29) and the washers that hold the torque converter housing to the flywheel housing.33. Remove spacer blocks (30) from between the torque converter housing and the front support of the rear axle. Remove floor jack (28) from under the transmission. 34. Install front mounting bolts (22) and the washers. Tighten the mounting bolts.35. Put disconnect switch (24) in position on the frame of the machine. Install the spacers, washers and bolts (27) which hold it.36. Reconnect wires (26) to the disconnect switch in their original locations.37. Reconnect wire cable (23). Connect grease tubes (25) to the fittings on the mounting bracket for the disconnect switch. 38. Connect tube assembly (21) to the fuel system.39. Connect tube assembly (20) to the fuel filter base.40. Connect three wires (17) to the starter solenoid in their original locations.41. Connect wire (19) to the electric starting motor. 42. Put control cable housing in position on the side of the governor. Install bolts (16) that hold it. 43. Install cover (15) on the fuel system. 44. Reconnect two wiring harnesses (14). 45. Fasten a lifting sling and a hoist to elbow (13) and put it in position on the rear of the engine. 46. Install two bolts (12) and four bolts (11) and the washers that hold elbow (13). Install the retainers and two bolts (8). Reinstall clamp (7), and tighten it.47. Reconnect tube assemblies (9) and (10). 48. Reconnect wiring harness (6) at the rear of the engine. 49. Connect three hoses (4) at the air compressor.50. Reconnect two heater hoses (5). Install all clips which hold the heater hoses to the side of the engine. Open the two heater hose valves. 51. Check the condition of the o-ring seals used in the two tube assemblies which are connected to the bottom of the transmission oil cooler. If the seals are worn or damaged, use new parts for replacement. Install the o-ring seals in the tube assemblies, and connect them to the bottom of the transmission oil cooler.52. Connect wiring harness (3).53. Reinstall bracket (1) on the side of the transmission oil cooler.End By:a. install rear drive shaft *b. install mufflerc. install radiator and guardd. install air cleaner elements and housing*This operation is in the Power Train Disassembly & Assembly module, Form No. SENR4771.