21542459 Volvo.Penta Wiring harness

Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-4030 Thread Lock Compound 1
B - Guide Bolt
M8 by 80 mm 2
C 319-6486 Alignment Tool 1
- Bolts
M10 by 50 mm 3
D - Straight Edge 1
E 1U-6396 O-ring Assembly Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the front housing is clean and free from damage. If necessary, replace the front housing. If necessary, install blanking plugs to a new front housing. Use Tooling (A) to seal all D-plugs.
Check the condition of the crankshaft front seal. If the front seal is damaged, remove the front seal from the front housing.
Clean the surfaces of the cylinder block.
Illustration 1 g01475069
Typical example
Install thrust washer (11) into the recess in the cylinder block. Refer to Disassembly and Assembly, "Camshaft - Install" for more information.
Illustration 2 g01475134
Typical example
Illustration 3 g01269947
Typical example
Install Tooling (B) to the cylinder block. Refer to Illustration 2.
Install Tooling (C) to the cylinder block.
Align a new joint (6) with Tooling (B) and Tooling (C). Install the joint to the cylinder block. Note: Ensure that Tabs (X) on the joint are engaged in Holes (Y) in the cylinder block.
Install the front housing over Tooling (B) and over Tooling (C) onto the cylinder block.
Illustration 4 g01269948
(7) M8 by 20 mm
(8) M8 by 35 mm
(9) M8 by 25 mm
Install bolts (9) to front housing (3) finger tight.
Remove Tooling (B).
Loosely install bolts (7) and (8). Refer to Illustration 4 for the correct position of the bolts.
Align the bottom face of front housing (3) to the lower machined face of the cylinder block. Use Tooling (D) and a feeler gauge in order to check the alignment between the front housing and the cylinder block. Refer to Illustration 3. Refer to Specifications, "Front Housing and Covers" for further information.
Illustration 5 g01269949
Tightening sequence for the front housing
Tighten bolts (7), (8) and (9) to a torque of 28 N m (20 lb ft). Tighten the bolts in the sequence that is shown in Illustration 5. Note: Ensure that the housing and the cylinder block are correctly aligned.
Remove Tooling (C) from the cylinder block.
If necessary, install a new crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front Seal - Remove and Install".
Illustration 6 g01475068
Typical example
If the engine is equipped with a heavy duty idle gear. Install plate (6). Refer to Disassembly and Assembly, "Idler Gear - Install" for the correct procedure.
Illustration 7 g01475066
Typical example
Install new O-ring seal (4) and O-ring seal (5) to bypass tube (2). Use Tooling (E) in order to lubricate O-ring seal (5). Install bypass tube (2) to front housing (3). Install bolts (1). Tighten the bolts to a torque of 22 N m (16 lb ft). Note: Ensure that any brackets that are secured by the bolts are installed in the correct location.
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure. End By:
Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install".
Install the timing gears. Refer to Disassembly and Assembly, "Gear Group (Front) - Remove and Install".
Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".
Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley - Remove and Install".
Install the alternator. Refer to Disassembly and Assembly, "Alternator - Install".
Install the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install".