21163201 Volvo.Penta Wiring harness

Table 1
Required Tools
Tool Part Number Parts Description Qty
A 370-8376 Capping Kit 1 Start By:
If necessary, remove the secondary fuel filter and the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure.
If necessary, remove the water separator and fuel filter (Primary). Refer to Disassembly and Assembly, "Fuel Water Separator and Fuel Filter (Primary) - Remove and Install" for the correct procedure.
Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install" for the correct procedure.
Remove the fuel manifold. Refer to Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install" for the correct procedure.
Remove the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" for the correct procedure.
Remove the glow plugs. Refer to Disassembly and Assembly, "Glow Plugs - Remove and Install" for the correct procedure.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure.
Illustration 1 g02452914
Disconnect the upper radiator hose from water temperature regulator housing (1) on the cylinder head.
Illustration 2 g02452915
Follow Step 3.a through Step 3.b in order to disconnect harness assembly (7) from boost pressure sensor (5).
Slide the locking tab into unlocked position (4).
Disconnect harness assembly (7) from boost pressure sensor (5).
Follow Step 4.a through Step 4.b in order to disconnect harness assembly (6) from inlet air temperature sensor (3).
Slide the locking tab into unlocked position (2).
Disconnect harness assembly (6) from inlet air temperature sensor (3).
Remove all cable straps that secure harness assembly to the cylinder head. The harness assembly should be positioned away from the cylinder head in order to avoid causing an obstruction during the removal of the cylinder head.
Illustration 3 g02452919
Disconnect plastic tube assembly (8) and plastic tube assembly (11) from tube assembly (15). Use Tooling (A) in order to plug the plastic tube assemblies and to cap the tube assembly.
Disconnect hose assembly (13) from connection on tube assembly (15). Remove O-ring seal (14) (not shown). Use Tooling (A) in order to plug the hose assembly and to cap the tube assembly.
Use a suitable tool in Position (X) in order to hold tube assembly (15) as nut (12) is loosened. Remove bolt (16) from tube assembly (15).
Remove tube assembly (15) from the bracket and the cylinder head. Use Tooling (A) in order to plug the cylinder head and to cap the tube assembly.
Remove O-ring seal (15) from tube assembly (17).
Illustration 4 g02456139
Disconnect plastic tube assembly (18) plastic tube assembly (20) and plastic tube assembly (21) from clips (22) and clips (24).
Remove bolts (23) from fuel filter bracket (19).
Remove fuel filter bracket (19) from the cylinder head.
Illustration 5 g02452920
Follow Step 14.a through Step 14.c in order to disconnect harness assembly (26) from coolant temperature sensor (25).
Slide locking tab (27) into the unlocked position.
Disconnect harness assembly (26) from coolant temperature sensor (25).
Cut cable strap (28) and remove harness assembly (26) from bypass tube (30). The harness assembly should be positioned away from the cylinder head in order to avoid causing an obstruction during the removal of the cylinder head.
Remove bolts (29). Remove bypass tube (30) from the cylinder head. Remove O-ring seal (31) and O-ring seal (32) from bypass tube (30).
Illustration 6 g02452921
Illustration 7 g02452922
Sequence for tightening the bolts for the cylinder head
Gradually loosen bolts (33) in the reverse numerical order to the tightening sequence. Refer to the Illustration 7. Note: Follow the correct sequence in order to help prevent distortion of the cylinder head.
Remove bolts (33) from cylinder head (34).
Attach a suitable lifting device to cylinder head (34). Support the weight of the cylinder head. The weight of the cylinder head is approximately 66 kg