20459155 Volvo.Penta Pulley

Identify and mark all lines, hoses and electrical wiring before removing or disconnecting for purposes of reassembly.1. Remove six bolts (1) and cover (2) from the governor control housing.2. Disconnect the electrical wires from solenoid (3).3. Disconnect the ground wires from starter (4).4. Disconnect fuel line (5). 5. Mark the position of lever (6) on the governor shaft for purposes of reassembly. Remove lever (6) from the governor shaft.6. Remove the two bolts and governor control housing (7) from the engine. 7. Remove the bolts from the support clips for governor control cable (9) and wiring harness (11).8. Remove the bolts and plates (8) and (10). 9. Remove the bolt and fitting assembly (12) from air conditioner compressor (14). Plug and cap all openings to prevent contamination and debris from entering the system.10. Remove connector (13) from the support clip. Disconnect connector (13).11. Remove air conditioner compressor (14). Refer to the topic "Remove & Install Air Conditioner Compressor" in this module for further information. Identify and mark all lines, hoses and electrical wiring for purposes of reassembly.12. Disconnect fuel line (15) from the fuel injection pump. Plug and cap all openings to prevent contamination from entering the system.13. Remove the wire ties, bolts and clips holding wiring harness (16) to the engine.14. Disconnect the wire harness (16) from alternator (17). 15. Remove the wire ties and wiring harness support clips holding the wires for switch (18) and switch (19). Disconnect the wires from switch (18) and switch (19).16. Remove the support clamp holding hose (22).17. Loosen the hose clamp and disconnect heater hose (21).18. Remove the support clamps and breather tube (20). 19. Remove the wire ties, bolts and clips holding wiring harness (24) to the engine. Disconnect the wires from switch (25).
To prevent possible personal injury, make sure all the pressure in the air system has been released before any air lines are disconnected.
20. Release the air pressure from the system. Refer to the Operation & Maintenance manual for further information.21. Remove the support clamps and disconnect three hoses (23) from the air compressor.22. Disconnect heater hose (26).
Typical Example23. Drain the oil from the transmission.24. Remove four bolts from the flange end of tube assembly (27) to disconnect tube (27) from the engine. Position tube (27) clear of the engine.25. Remove four bolts from the flange at each end of tube (28). Remove tube (28). 26. Remove the washer, sleeve and bolt (29) from upper mount (30) at each side of the engine.27. Remove upper mount (30) from each side of the engine. 28. Support the engine with a hoist and tooling (A). Attach tooling (A) to lifting brackets (31) as shown.
The torque convertor can drop if not supported by a floor jack or suitable blocks. To avoid personal injury or component damage, make sure the torque convertor is properly supported when removing or installing the engine.
29. Use a floor jack and wooden block to support the torque convertor as shown. If necessary, use forcing screws to make a separation of the transmission case and the flywheel housing.30. Remove bolts (32) that hold the torque converter to the flywheel housing. Remove the engine from the machine. The weight of the engine is 805 kg (1775 lb.).31. Check the condition of two upper and lower engine mount assemblies (30). If the mount assemblies are worn or damaged, use new parts for replacement. The following steps are for the installation of the engine.32. Position lower engine mount assemblies (3) into each side of the frame. 33. Inspect O-ring seal (33) on the torque converter. Replace with a new O-ring seal if worn or damaged. Put 1U6395 O-Ring Compound on O-ring seal (33). 34. Use a hoist and tooling (A) to position the engine in the machine frame as follows: a. Move the engine onto the torque converter. Make sure the teeth of the flywheel housing and the teeth of the torque converter align.b. Install bolts (32).c. Remove the jack and wooden block supporting the torque converter. 35. Install the sleeve, bolt, washer and upper engine mount (30) onto both sides of the engine and frame.36. Remove the hoist and tooling (A).37. Reverse procedures and steps 1 through 25 to complete the installation of the engine.38. Fill the transmission with fluid to the correct level. Refer to the Operation & Maintenance manual for further information.End By:a. install rear drive shaft *b. install radiator and guardc. install air cleanerd. install hood*Refer to the Power Train Disassembly & Assembly module for this information.