21928775 Volvo.Penta Charge air cooler

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     FT-1114     Vacuum Cap     1    
9S-8008 O-Ring Plug     1    
3D-2824 O-Ring Seal     1    
B     138-7574     Link Brackets     2    
C     3S-6224     Electric Hydraulic Pump Gp     1    
6V-3160 Double Acting Cylinder     1    
7F-6088 Sleeve     1    
D     -     Threaded Rod
3/4 - 10 by 24 in.     1    
5P-8248 Hard Washers     2    
2J-3506 Full Nut     2    
E     376-8697     Puller Stud     1    
5P-8247 Hard Washer     1    
4K-0367 Full Nut     1    
F     4C-9633     Puller Stud     1    
5P-8250 Washer     1    
9U-6833 Nut     1    
G     5P-2145     Bearing Puller Adapter     1    
H     1P-1834     Bearing Puller Adapter     1    
When you are using hydraulic cylinders and puller studs, always ensure that the rated capacity of the puller stud meets or exceeds the rated capacity of the hydraulic cylinder. If the puller stud does not meet or exceed the rated capacity of the hydraulic cylinder, a sudden failure of the puller stud could occur. The sudden failure of the puller stud could result in personal injury or death.
Personal injury can result from hydraulic oil pressure and hot oil.Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.
Personal injury can result from hot coolant, steam and alkali.At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand.Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.
Personal injury can result from contact with refrigerant.Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area.Personal injury or death can result from inhaling refrigerant through a lit cigarette.Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death.Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.
Do not use Polyalkylene Glycol (PAG) oil in the compressor. Use Polyol Ester (POE) oil. The use of any other oil will cause rapid dielectric failure of the compressor.
Illustration 1 g02604618
Position the tracks. Pins (1) must be positioned, as shown.
Remove the hood.
Remove the engine side guards.
Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining and filling procedure.
Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct recovery and charging procedure. Refer to Special Publication, NENG2500, "Air Conditioning To