961161 Volvo.Penta Washer

1. Put identification on all hoses during the disassembly procedures for installation purposes.2. Disconnect heater hoses (1) and (2) from the water pump elbow and the transmission oil cooler bonnet. Disconnect hose assemblies (3) from the air compressor governor fittings. 3. Disconnect three hose assemblies (4) from the hydraulic oil pump.
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. SENR3334 for more information on removal and installation of lines and refrigerant from the system.
Optional4. Disconnect air conditioner lines (5) from the air conditioner compressor. 5. Remove three clips (7) and disconnect battery cable (8) from the disconnect switch. Disconnect wiring harness (6). 6. Disconnect fuel line (10) from the fuel transfer pump. Disconnect linkage assembly (9) from the governor lever. Remove two bolts that fasten bracket (11) to governor. 7. With valve in the "OFF" position disconnect fuel line (12) from the fuel filter group. 8. Loosen two clamps (14) and remove swivel (13) from the turbocharger and muffler elbows. 9. Put identification on wires and cables (15) and disconnect them from the electric starting motor. 10. Loosen clamps and remove hose (16) from precleaner. Remove precleaner (17) from the air cleaner. 11. Disconnect hose assembly (18) from pipe assembly. Loosen two hose clamps (20) and slide hose (19) on pipe assembly. 12. Remove clip (21) that fastens hose assembly (18) to bracket. Remove the bolts that fasten the air cleaner assembly to bracket (23). Remove brace (22) and the air cleaner assembly. 13. Disconnect tachometer cable (24) from the governor. 14. Disconnect two clips (26) and three hose assemblies (25) from the axle suspension selector valve. 15. Remove bolt (27) from bracket and fasten (tie) the hose assemblies away from the rear of the engine. 16. Disconnect wiring harness plugs (28) and (29) from the rear of the engine. 17. Disconnect three hoses (30) from the torque converter. 18. Remove four bolts and clips (31) that fasten hose assemblies to the bottom of the engine. 19. Disconnect three hoses (32) from the transmission and scavenge pump. 20. Disconnect hose (33) and remove drive shaft (34) from the torque converter. 21. Disconnect hose assembly (35) and remove support caps (36) from each side of the engine. 22. Install a hoist and tooling (A) on engine. 23. Remove two bolts (38) that fasten the engine front support to frame.24. Remove engine (37) from the vehicle. Weight of the engine is 1383 kg (3050 lb.).Install Engine
1. Install tool (A) and hoist on engine (1) and put it in position in vehicle. 2. Install two front support mounting bolts (2). 3. Install support caps (4) to rear of engine. Connect hose assembly (3). 4. Install drive shaft (5) on torque converter and connect hydraulic hose assembly (6). 5. Connect three hose assemblies (7) to the transmission and scavenge pump. 6. Install four clips (8) that fasten the hose assemblies in place. 7. Connect three hose assemblies (9) to the torque converter. 8. Connect wiring harness plugs (10) and (11). 9. Put bracket (12) in position and install mounting bolt (13). 10. Connect three hose assemblies (14) to the axle suspension valve. Install two clips (15) in place. 11. Connect tachometer cable (16) to the governor. 12. Put air cleaner (17), hose clip (19) and brace (18) in position and install mounting bolts. 13. Connect hose assembly (20) on pipe assembly.14. Slide hose (21) in position on the turbocharger and pipe assembly. Tighten hose clamps. 15. Install precleaner (22) in position on the air cleaner. Tighten clamp bolt (24) to a torque of 25 7 N m (20 5 lb.ft.). Connect hose (23) as precleaner. 16. Connect wires and cables (25) to the electric starting motor. 17. Install swivel (26) in position between the turbocharger and muffler elbows. Put 5P3931 Anti-Seize Compound on bolt threads and tighten clamp bolts (27) to a torque of 20 7 N m (15 5 lb.ft.). 18. Connect fuel line from the fuel filter group to valve (28). Turn valve to the "ON" position. 19. Connect fuel line (29) to the fuel transfer pump. Connect linkage assembly (30) to the governor lever. Install bracket (31) on governor. 20. Connect battery cable (34) to the disconnect switch. Connect wiring harness (32) and install three clips (33).
Optional21. Install air conditioner lines (35) to the compressor.22. See AIR CONDITIONING AND HEATING SERVICE MANUAL, Form No. SENR3334, for correct procedure for evacuating and charging the system. 23. Connect three hose assemblies (36) to the hydraulic pump. 24. Connect heater hoses (38) and (37) to the water pump elbow and the transmissi