843820 Volvo.Penta Suction pipe

1. Remove six bolts and washers (3). Remove fan blade (2) and shroud (1). Remove side panel (17) from both sides of the engine. 2. Loosen two bolts (5) & (6) and remove the muffler. Remove clamp (4). Remove three bolts (7). 3. Attach a lifting device to the muffler and bracket and remove from the engine. The weight of the muffler and bracket is 30 kg (65 lb). 4. Remove two fuel lines (8) & (10). Remove clamps (11) as necessary. Remove wire (7). Remove throttle cable (9). 5. Remove wire (12) and wires (13) to the injection pump and vibratory pump. Move the wiring harness out of the way. Remove the clamps on the wiring harness as necessary.6. Remove four hydraulic lines (16) to the vibratory pump. Remove hose bulkhead (15) from the engine mount. Remove four engine mount bolts (14). 7. Remove two wires (18) from the positive terminal of the starter. Remove two wires (19) from the negative terminal of the starter. Remove ground wire (20). 8. Remove two wires (22) from the alternator and remove clamps (23) as necessary to move the wiring harness away from the engine. Remove wire (21) from the water temperature sending unit (not shown). 9. Remove four cab mount bolts (24). Remove two bolts (25) from each side of the cab and install the larger bolt into the center hole on each side. 10. In Step 11, the cab will be raised. The cab will pivot on bolts (26) and after the cab is raised, install the remaining two bolts (24) from Step 9 in holes (27) to hold the cab in position. Be sure to install a bolt in both sides of the cab. 11. Use a puller (A) to raise the cab as shown. After the cab is raised, install the two bolts in holes (27) in Step 10. 12. Install puller (A) as shown. 13. Attach puller (A) to the pumps as shown and support the weight of the pumps with the puller. Remove four bolts (28) and move the pumps away from the engine. 14. Attach lift fixture (B) to the engine and a lifting device. Slowly raise the engine and move it away from the machine. Watch hoses (29) and feed them through the holes in the engine mount. The weight of the engine is approximately 590 kg (1300 lb). The following steps are for the installation of the engine. 15. Attach lift fixture (B) to the engine and a lifting device. Position the engine in the machine. Watch hoses (29) and feed them through the holes in the engine mount. The weight of the engine is approximately 590 kg (1300 lb). 16. Use puller (A) to put the pumps in position. Install four bolts (28). 17. Remove puller (A) from the ROPS. 18. Install puller (A) as shown in position to lower the operator station. 19. Remove the bolts from holes (27) on both sides and lower the operator station. Remove bolts (26). 20. Install bolts (25). Install four bolts (24). 21. Install wires (22) to the alternator. Install clamps (23) on the wiring harness. Install wire (21) to the water temperature sensor(not shown). 22. Install wires (18) & (19) to the starter and solenoid. Install ground wire (20). 23. Install engine mount bolts (14). Install hoses (16) to the vibratory pump. Install wires (13) to the vibratory pump and fuel injection pump. Install wire (12). 24. Install wire (7). Install throttle cable (9). Install fuel lines (8) & (10). Install clamps (11). 25. Install the air cleaner and bracket, using a lifting device. 26. Install clamp (4). Install the muffler with clamps (5) & (6). 27. Position fan shroud (1) as shown. Fasten fan blade (2) with six bolts (3).End By:a. install oil coolerb. install radiatorRemove & Install Starter
1. Raise the left side door. Use two people to remove two stops (1) from the door and install a lifting strap as shown.2. Remove the bolts that fasten door (2) to the hood and use a lifting device to remove the door. The weight of the door is 50 kg (110 lb). 3. Remove panel (3). Mark wires (4) with identification for installation purposes.4. Remove six wires (4) from the starter. 5. Fasten a lifting strap to the starter. Fasten a lifting device to the lifting strap. Remove three bolts (5) and remove the starter. The weight of the starter is approximately 27 kg (60 lb). To install starter, reverse the removal steps.