20881388 Volvo.Penta Shim

Start By:a. remove engine enclosure groupFluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Products Guide", NENG2500 for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.1. Drain the oil from the hydraulic oil tank into a suitable container for storage or disposal. The capacity of the hydraulic oil tank is 205 liters (53.3 U.S. gal). 2. Put a suitable floor jack in position under step group (2) on the engine side of the machine. Fasten the step group to the floor jack.3. Remove four bolts (1) that hold step group (2) in position. Two bolts are located at the front of the step group. Two bolts are located at the rear of the step group.4. Carefully lower the step group and remove it from the machine. The weight of the step group is 113 kg (250 lb).
View From Under Machine5. Remove eight hex head fasteners (4). Remove front cover (5) and rear cover (3) from under the engine.
At Operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure in the cooling system. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
6. Release the pressure in the cooling system by slowly loosening the fill cap on the radiator.7. Drain the coolant from the cooling system into a suitable container for storage or disposal. The capacity of the cooling system is 35 liters (9.1 U.S. gal). 8. Loosen the two clamps, and remove upper radiator hose assembly (6). 9. Loosen the two clamps, and remove lower radiator hose assembly (7). 10. Remove tie wrap (10). Loosen clamp (8). Disconnect heater hose (9) from the engine. Loosen clamp (12). Disconnect heater hose (11) from the engine. 11. Close fuel supply valve assembly (14). Disconnect hose assembly (13) from the fuel priming pump. Put a plug in the end of the hose assembly to prevent loss of fuel. Disconnect hose assembly (15) from the fuel priming pump. Put a plug in the hose assembly to prevent loss of fuel. 12. Remove the electrical wires from the left and right side of water temperature regulator housing (16).13. Put identification marks on all wires (17) connected to the back side of the alternator. Disconnect the wires from the back side of the alternator. Remove clip (18).14. Cut all tie wraps. Disconnect electrical connector (19) at the water pump.15. Remove clip (21). Remove the bolt and washer that hold alternator/starter ground wire (20) to the cylinder block. 16. Put identification marks on all cables (22) and cables (23) that are connected to the electric starting motor and the starter solenoid. Disconnect all cables from the electric starting motor and starter solenoid. 17. Put identification marks on all hose assemblies (25) and tube assemblies (24) that are connected to the main hydraulic pump, the swing pump and the swing charge pump for installation purposes. Disconnect the hose assemblies and tube assemblies from the pumps. Put plugs in all hose assemblies and tube assemblies to prevent oil loss and to keep dirt and debris out of the hydraulic system.
View From Under Engine18. Disconnect hose assemblies (26), (27) and (28) from the brake/pilot pump. The brake/pilot pump is located on the lower left front of the engine. 19. Disconnect upper hose assembly (30) for the brake/pilot pump at firewall connection (29). 20. Disconnect wiring harness (31) for the governor cylinder. 21. Remove clip (33). Disconnect wire assembly (32) from the governor cylinder. 22. Disconnect hose assemblies (34) and (35) from the governor cylinder. Put plugs in the ends of the hose assemblies. 23. Put identification marks on three wires (36) that are connected to the fuel shutoff solenoid. Disconnect the three wires from the fuel shutoff solenoid. 24. Remove tie wrap (37) from the wires that are routed to the fuel shutoff solenoid and the air conditioning compressor. 25. Disconnect wiring harness (38) for the air conditioning compressor. 26. Loosen bolts (39) and (40). Remove the nuts, washers and bolts (41) that hold plate (42) to air conditioning compressor (43). 27. Remove the air conditioning compressor mounting bolt (44), the washer and nut. Carefully lift the air conditioning compressor from the engine, and lay it to the side, out of the way. 28. Disconnect fuel hose assemblies (45) and (46). Put plugs in the ends of the hose assemblies to prevent fuel loss and to keep dirt out of the fuel system. 29. Disconnect pressure switch electrical connector (47). 30. Remove two tie wraps (48) from the wiring harness for the engine speed senor. Disconnect wiring harness (49). 31. Fasten Tool (A) and a hoist to the engine as shown.32. Remove four engine mounting bolts (50) that hold the engine to the frame of the machine.
Prior to removing the engine and main hydraulic pump from the machine, make sure all hose assemblies, tube assemblies and wires have been disconnected properly.
33. Carefully remove engine and main hydraulic pump (51), as a unit, from the machine. The combined weight of the engine and main hydraulic pump is 816 kg (1800 lb). 34. Remove two mounting bolts (52) and front engine mounting bracket (53). Remove the other front engine mounting bracket. 35. Remove two mounting bolts (54) and rear engine mounting bracket (55). Remove the other rear engine mounting bracket. The following steps are for the installation of the engine and main hydraulic pump.
Visually check the condition of the rubber mounts in the front and rear engine mounting brackets. If the rubber mounts are worn or damaged