20778493 Volvo.Penta Plug

Table 1
Required Tools
Tool Part Number Part Description Qty
A(1) 9U-6198 Crankshaft Turning Tool 1
A(2) 5P-7306 Shaft Housing 1
5P-7305 Engine Turning Tool 1
B 136-4632 Timing Pin
(Crankshaft) 1
268-1966 Adapter 1
C 1P-2320 Combination Puller 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.
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.Dispose of all fluids according to local regulations and mandates.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Put identification marks on all hoses, on all hose assemblies and on all tube assemblies for installation purposes. Plugging all hose assemblies and tube assemblies. Plugging all hose assemblies and tube assemblies helps to prevent fluid loss. Plugging helps to keep contaminants from entering the system.
Do not disconnect the air lines until the air pressure in the system is at zero. If hose is disconnected under pressure it can cause personal injury.
Release the pressure from the air system. Refer to the Original Equipment Manufactures (OEM) for the correct procedure.
Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure.
If the engine is equipped with a hydraulic pump on the rear of the air compressor, remove the hydraulic pump. Refer to the OEM for the correct procedure.
Use Tooling (A) to rotate the crankshaft so that number one piston is at the top center position on the compression stroke. Refer to Systems Operation, Testing and Adjusting, "Fuel Injection Timing - Check" for the correct procedure.Note: The air compressor must be timed with the engine to minimize engine vibration.
Illustration 1 g02429600
Remove plug (1) from the cylinder block. Remove O-ring seal (2) from the plug.
Install Tooling (B) into Hole (X) in the cylinder block. Use Tooling (B) to lock the crankshaft in the correct position.Note: Do not use excessive force to install Tooling (B). Do not use Tooling (B) to hold the crankshaft during repairs.
Illustration 2 g02429596
Illustration 3 g02429597
Slide hose clamps for coolant hose (3) and coolant hose (4) along the hose assemblies.
Disconnect coolant hose (3) and coolant hose (4) from the connections on air compressor (6).
Disconnect the air lines from port (5) (not shown) and air lines from port (7). Refer to the OEM for the correct procedure.
Remove banjo bolt (9) and remove sealing washers (11) (not shown) from air compressor (6).
Remove bolts (10) and bolts (13) from support bracket (12) and remove the support bracket.
Support air compressor (6). Remove nuts (16) and remove the air compressor from front housing (8).
If necessary, remove studs (15) from front housing (8).
If necessary, remove bolts (18) and remove plate (17). Remove O-ring seal (14) from plate (17).
Illustration 4 g02429598
Remove O-ring seal (23) from adapter (24).
If necessary, follow Step 16a through Step 16b to remove gear (22) from the crankshaft of the air compressor.
Use a suitable tool to prevent the crankshaft of the compressor from rotating. Remove nut (20) and remove spring washer (21).
Use Tooling (C) to remove gear (22) from the crankshaft of air compressor (6).
If necessary, follow Step 17 through Step 17c to remove adapter (24) from air compressor (6).
Remove bolts (19) from adapter (24).
Remove adapter (24) from air compressor (6).
Remove O-ring seal (25).