3803403 Volvo.Penta Cylinder head, exch

Start By:
Install the wheel chocks. Refer to Disassembly and Assembly, "Wheel Chock (Front and Rear) - Remove and Install".
Connect the frame lock link. Refer to Disassembly and Assembly, "Frame Lock Link - Separate and Connect".
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.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
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 filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.
Note: Install caps and plugs on all openings in order to prevent dirt or debris from entering the system. Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.Note: For easier assembly, mark all hose assemblies, tube assemblies, wire harnesses and cables for identification purposes.
Illustration 1 g00598437
The view is on the back of the engine end frame under the front of the engine.
Illustration 2 g00598441
The view is on the right side of the engine end frame under the left side of the engine.
Drain the cooling system. Loosen drain plug (1) in order to drain the radiator. Loosen drain plug (2) in order to drain the cooling system.
Refer to Operation and Maintenance, "Cooling System Coolant (ELC) - Change" for the appropriate procedure to drain the cooling system. The capacity of the cooling system is 500 L (132 US gal).
Illustration 3 g00598860
Illustration 4 g00598861
This view is under the right side of the engine along the left side of the engine end frame.
Open the lower door assembly on the left side of the machine. Remove two hose clamps (3) and (4) that secure hose (5) to the water manifold and tube (6) .
Remove hose (5) from the water manifold and tube (6) .
Remove the bolt, the washers, and the nut that secures clip (7) and clip (8) to the bracket on the left side of the engine end frame.
Remove clip (7) and clip (8) from tube (6) .
Illustration 5 g00598864
Remove the bolt, the washers, and the nut that secures clip (9) (not shown) and clip (10) to bracket (11) .
Remove clip (9) (not shown) and clip (10) from tube (6) .
Remove two bolts (12), the washers, the retainer, and the retaining ring that secures tube (6) and the O-ring seal to brake oil cooler (13) .
Remove tube (6) from brake oil cooler (13) .
Loosen hose clamp (14). Disconnect hose (15) from brake oil cooler (13) .
Illustration 6 g00598867
Disconnect two hose assemblies (16) and (17) from block (18) on brake oil cooler (13) .
Disconnect hose assembly (19) from check valve (20). Disconnect hose assembly (21) from block (22) .
Illustration 7 g00598868
Attach a suitable lifting sling around brake oil cooler (13). Secure the suitable lifting sling to a hoist.
Remove two bolts (23) and the washers that secure bracket assembly (24) to the left side of the engine end frame.
Remove two bolts (25) and the washers that secure bracket assembly (26) to the left side of the engine end frame.
Remove brake oil cooler (13) and two bracket assemblies (24) and (26) from the left side of the engine end frame.
The weight of brake oil cooler (13) and two bracket assemblies (24) and (26) is 52 kg (115 lb).
Remove two bolts (27) that secure bracket assembly (26) to brake oil cooler (13). Remove two bolts (28) that secure bracket (11) and bracket assembly (24) to brake oil cooler (13) .
Remove bracket (11) and two bracket assemblies (24) and (26) from brake oil cooler (13) .