240688 Volvo.Penta Plug

2. Remove sheet assembly (1) from the right hand side of the machine. 3. Loosen clamps (2) on the turbocharger and the air cleaner pipe assembly. Slide hose (3) on pipe.4. Remove cotter pin and pin (6) to disconnect linkage rod (5) from governor.5. Disconnect hose assembly (4) from the fuel filter base housing. 6. Disconnect air line tube assemblies (7). 7. Put identification on and disconnect all alternator (9) and electric starting motor wires (8). 8. Remove clip (11) and loosen clamp to remove heater hose (10) from the water pump fitting if equipped. 9. Loosen clamps (13), slide hose on elbow and remove elbow (12) and gasket from the cylinder head. 10. Remove clip (15) and water temperature indicator (14) from the cylinder head. 11. Remove sheet panel assembly (16) from the left hand side of the machine. 12. Remove bulldozer guard assembly (17) from the left hand side of the machine. 13. Put identification on hose assemblies (19) for installation purposes. Disconnect hoses. Loosen nuts (20) and move tube assemblies (18) from support. 14. Put identification on both the steering hose assemblies (22) and disconnect from elbow fittings. Remove bolt (23) and bracket that fasten steering tube assemblies (21) to frame. 15. Remove flanges (24) to disconnect oil supply line (25) from elbow. 16. Remove bolts and flanges that fasten steering lines (26) and (27) and elbow (28) to the steering valve. 17. Remove the differential to transmission drive shaft (29). 18. Remove the bolt from the front timing gear cover and install tooling (B). 19. Install spacer and tooling (C) for clearance to prevent damage to the fuel injection nozzle and the rocker shaft assembly. 20. Install tooling (A) in position to support and lift the torque converter and transmission. 21. Install tooling (D) and a hoist on the engine as shown. 22. Remove twelve bolts (30) that fasten the torque converter housing to the flywheel housing. 23. Remove two bolts (31) and (32) that fasten the engine front support to the frame.24. Remove the engine from vehicle. The weight of the engine is 1600 lb. (726 kg)Install Engine
Before any installation procedures are done inspect all O-ring seals and make any replacements if necessary. 1. Put lubricant on the torque converter O-ring seal and install engine (1) in chassis with tooling (A). 2. With tooling (B) in position, make an alignment of the torque converter housing (2) to the flywheel housing. 3. Install twelve bolts (3) to fasten torque converter housing to the flywheel housing. 4. Install bolts (4) to fasten support assembly (5) to frame.5. Remove tooling (A) and tooling (B). 6. Install drive shaft (6) in position and tighten bolts to a torque of 35 4 lb.ft (45 5 N m). 7. Install elbow (9) and tube assemblies (7) in position on the steering valve.8. Put oil supply line hose (8) in place on elbow and install flanges and bolts. 9. Put tube assemblies in position and install bracket (11) and bolt. Connect steering hose assemblies (10) to fittings. 10. Tighten nuts (14) to fasten tube assemblies (12) in position on support. Connect steering line hoses (13). 11. Install bulldozer guard assembly (15) on the left hand side of machine. 12. Install sheet panel assembly (16) on the left hand side of the vehicle. 13. Install water temperature indicator (17) and clip (18) in position on the cylinder head.14. Inspect elbow gasket and make a replacement if necessary. 15. Install elbow (20) on cylinder head. Slide hose from turbocharger on to elbow. Tighten two hose clamps (19). 16. If equipped, install hose (21) from water heater to the water pump elbow.17. Install clip (22) in position on water pump. 18. Connect wires to the steering motor and to the alternator. 19. Connect two tube assemblies (23). 20. Slide hose (25) from the air cleaner pipe to the turbocharger. Install two hose clamps (24).21. Put governor control linkage (27) in position and install pin (28) and cotter pin.22. Install fuel line (26) to the fuel filter base. 23. Install sheet assembly (29) on the right hand side of the machine.END BY:a) install water separatorb) install valve coverc) install air tankd) install radiator and guard