3802062 Volvo.Penta Turbocharger

Always wear goggles when the air conditioning system is opened. This system is charged with Freon-12 (CCL2F2- Dichlorodifluoromethane) which is not toxic or flammable. But there is a reason for caution. When Freon- 12 makes contact with a flame, lethal phosgene gas is made. INHALING FREON THROUGH A LIGHTED CIGARETTE CAN CAUSE VIOLENT ILLNESS. This system is under pressure at all times, engine running or not. HEAT MUST NEVER BE PUT ON A CHARGED SYSTEM. See AIR CONDITIONING AND HEATING SERVICE MANUAL Form No. SENR7454 for more information on procedures and safety requirements on removal and installation of lines and refrigerant from the system.
1. Disconnect refrigerant lines (3) from the air conditioning compressor. Put identification on the refrigerant lines for correct installation.2. Disconnect wire harness (2) from the air conditioning compressor. Put identification on the wires for correct installation.3. Bend clips (1) and (4) open and remove wires and water temperature line from the clips. 4. Bend clip (5) open and remove wires and water temperature line from the clip. 5. Remove water temperature sensing unit (6) from the cylinder head. 6. Disconnect fuel lines (8) and (9). Put plugs in the openings.7. Bend clips (7) and (10) open and remove the wire harness from the clips.8. Disconnect the wire from the alternator. 9. Disconnect governor linkage (14) from the lever.10. Disconnect wire (13) from the sensing unit in the rear of the cylinder head.11. Disconnect the oil pressure line (12) and remove it from clip (11) on the left side of the engine lifting bracket.12. Disconnect the fuel pressure line and remove it from the clip on the right side of the engine lifting bracket. 13. Disconnect wires (15) and (16) from the starting motor. 14. Drain the hydraulic tank. Disconnect tube assembly (17) from the hydraulic pump. Use tool (A) to pull the tube assembly up out of the way.15. Disconnect oil line (18) from the bottom of the hydraulic pump. 16. Disconnect coolant lines (19) and (20) from the shutoff valves.
VIEW FROM UNDER THE MACHINE17. Disconnect oil lines (21) and (22) from the scavenge pump.
VIEW FROM UNDER THE MACHINE18. Drain the torque converter housing. Disconnect bracket (28) from the torque converter housing.19. Disconnect oil lines (26) and (27) from the torque converter housing.20. Disconnect oil line (25) from the torque converter relief valve.21. Disconnect oil lines (23) and (24) from the power train oil pump.
VIEW FROM UNDER THE MACHINE20. There will be a loss of oil when oil lines (25) and (29) are disconnected. Disconnect oil lines (25) and (29) from the transmission oil cooler. Remove oil line (25).23. Fasten a hoist to the engine. 24. Remove bolts (30), nuts and caps (31) that hold the rear supports to the frame on each side. 25. Remove bolts (32) that hold the front support to the frame on each side.
Make a final inspection to make sure all lines, hoses, wires and clips are clear of the engine and torque converter.
26. Remove engine (33) and torque converter as a unit from the machine. The weight is 4500 lb. (2025 kg).27. Remove the torque converter from the engine. See REMOVE TORQUE CONVERTER.Install Engine
1. Install the torque converter to the engine. See INSTALL TORQUE CONVERTER. Make sure the engine rear support blocks are in place on the frame. 2. Fasten a hoist to the engine. Put the engine and torque converter (1) in position on the frame. 3. Install caps (2), bolts (3) and nuts on each side of the rear supports. Tighten the bolts to a torque of 265 35 lb.ft. (360 47 N m). 4. Install bolts (4) on each side of the front support. Tighten the bolts to a torque of 150 20 lb.ft. (205 27 N m).
VIEW FROM UNDER THE MACHINE5. Connect oil line (6) to the transmission oil cooler. Connect oil line (5) to the transmission oil cooler. Connect the other end of oil line (5) to the torque converter outlet relief valve.
VIEW FROM UNDER THE MACHINE6. Connect oil lines (7) and (8) to the power train oil pump.7. Connect oil lines (9) and (10) to the torque converter housing.8. Connect bracket (11) to the torque converter housing.
VIEW FROM UNDER MACHINE9. Connect oil lines (12) and (13) to the scavenge pump. 10. Connect coolant lines (14) and (15) to the shutoff valves.11. Connect oil line (17) to the bottom of the hydraulic pump. 12. Lower pipe (16) in to place on the hydraulic pump and install the bolts that hold it. Remove tool (A). 13. Connect wires (18) and (19) to the starting motor. 14. Install water temperature sensing unit (20) in the cylinder head. 15. Connect governor linkage (24) to the lever.16. Connect oil pressure line (21) together. Put the oil pressure line in place in clip (22) on the left side of the engine lifting bracket.17. Connect the fuel pressure line together and put it in place in the clip on the right side of the engine lifting bracket.18. Connect wire (23) to the sensing unit in the rear of the cylinder head. 19. Connect the wire to the alternator. Put the wire harness in clips (25) and (28) and bend the clips closed.20. Remove the plugs and connect fuel lines (26) and (27). 21. Install the wires and water temperature line in clip (29). Bend the clip closed. 22. Install the wires and water temperature line in clips (30) and (33). Bend the clips closed.23. Connect wire harness (32) to the air conditioning compressor. See AIR CONDITIONING AND HEATING SERVICE MANUAL Form No. SENR7454 for correct procedure for evacuating and charging the system.24. Connect refrigerant lines (31) to the air conditioning compressor.25. After the end by steps, fill the transmission oil system to the correct level. See LUBRICATION AND MAINTENANCE GUIDE.end by:a) install universal joint *b) install fanc) install radiator and guard*This operation is in POWER TRAIN DISASSEMBLY AND ASSEMBLY section.