240606 Volvo.Penta Cover

At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Drain the coolant only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to avoid personal injury.
1. Position a suitable container under the radiator. Loosen the radiator cap from the tank assembly. Remove the drain plug from the plug adapter, and drain the radiator below the level of the aftercooler. The capacity of the cooling system is 142 L (37 U.S. gal). For more information, refer to the topic "Drain And Refill Radiator" in this manual. 2. Remove two bolts (1), the washers, and plate (2) from aftercooler cover (3). 3. Remove four bolts (4), the washers, and bracket (5) from aftercooler cover (3). 4. Remove four bolts (6), the washers, and bracket (7) from aftercooler cover (3). 5. Remove two bolts (9), the washers, and bracket (8) from aftercooler cover (3). 6. Disconnect tube assembly (10) from manifold (11). Remove the clips that hold tube assembly (10) to the aftercooler housing. Set tube assembly (10) aside. Cap and plug tube assembly (10) to avoid system contamination. 7. Remove two bolts (12) and drain flange (13) from flywheel housing (14). 8. Remove sixteen bolts (15), the washers, and aftercooler cover (3) from the aftercooler housing. 9. Remove gasket (16) from aftercooler cover (3). 10. Remove eight bolts (17), the washers, the gasket, and adapter (18) from aftercooler cover (3). 11. Remove two bolts (22) and elbow (20) from tube assembly (19) and aftercooler housing (21). 12. Remove aftercooler adapters (23) and (24) from aftercooler housing (21). Remove O-ring seal (25) from tube assembly (19). 13. Remove aftercooler adapter (23) from aftercooler adapter (24). 14. Remove O-ring seal (26) from aftercooler adapter (24). Remove O-ring seal (27) from aftercooler adapter (23). 15. Remove two bolts (29), elbow (28), and coupling (30) from the connector. Remove coupling (30) from elbow (28). 16. Remove two O-ring seals (31) from coupling (30). 17. Remove aftercooler adapters (32) and (33) from aftercooler housing (21). 18. Remove aftercooler adapter (32) from aftercooler adapter (33). 19. Remove O-ring seal (34) from aftercooler adapter (33). 20. Remove O-ring seal (35) from aftercooler adapter (32). 21. Remove eight bolts (37), the washers, and aftercooler core assembly (36) from aftercooler housing (21).22. If necessary remove the 14 bolts and the washers that hold aftercooler housing (21). Remove aftercooler housing (21) and the gasket. 23. Remove four O-ring seals (38) from aftercooler core assembly (36). The following steps are for the installation of the water aftercooler.24. Make sure all components of the water aftercooler are clean of dirt and foreign material prior to installation. Remove all gasket material from the mating surfaces of the water aftercooler.25. Check all O-ring seals and components for wear or damage and replace if necessary.26. Lubricate all O-ring seals lightly with engine oil. 27. Install four O-ring seals (38) to aftercooler core assembly (36). 28. Put aftercooler housing (21) and the gasket in position on the engine. Install the 14 bolts and the washers that hold aftercooler housing (21). Install aftercooler core (36), eight bolts (37), and the washers to aftercooler housing (21). 29. Install O-ring seal (35) to aftercooler adapter (32). 30. Install O-ring seal (34) to aftercooler adapter (33). 31. Install aftercooler adapter (33) to aftercooler adapter (32). 32. Install aftercooler adapters (32) and (33) to aftercooler housing (21). 33. Install two O-ring seals (31) on coupling (30). 34. Install coupling (30) to elbow (28). Install coupling (30), elbow (28), and two bolts (29) to the connector. 35. Install O-ring seal (27) to aftercooler adapter (23). Install O-ring seal (26) to aftercooler adapter (24). 36. Install aftercooler adapter (23) to aftercooler adapter (24). 37. Install O-ring seal (25) on tube assembly (19). Install aftercooler adapters (23) and (24) to aftercooler housing (21). 38. Install elbow (20) and two bolts (22) to tube assembly (19) and aftercooler housing (21). 39. Install the gasket, adapter (18), eight bolts (17), and the washers to aftercooler cover (3). 40. Install gasket (16) on aftercooler cover (3). 41. Install aftercooler cover (3), sixteen bolts (15), and the washers to the aftercooler housing. 42. Install drain flange (13) and two bolts (12) to flywheel housing (14). 43. Connect tube assembly (10) and all the clips to the aftercooler housing. Connect tube assembly (10) to manifold (11). 44. Install bracket (8), two bolts (9), and the washers to aftercooler cover (3). 45. Install bracket (7), four bolts (6), and the washers to aftercooler cover (3). 46. Install bracket (5), four bolts (4), and the washers to aftercooler cover (3). 47. Install plate (2), two bolts (1), and the washers to aftercooler cover (3).48. Remove the radiator cap from the tank assembly and fill the radiator. Install the radiator cap on the tank assembly. The capacity of the cooling sy