20459234 Volvo.Penta Exhaust pipe

Start By:a. install body retaining pins Fluid Spillage ContainmentCare must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Product Guide, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gage to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
1. Drain the coolant from the engine cooling system in a suitable container. The capacity of the cooling system is 221 liters (58.5 U.S. gal). 2. Open front hood assembly (3). Remove four bolts (4) and the washers that hold front hood assembly (3) to the frame assembly. Remove cotter (1) and the washer that holds prop assembly (2) to front hood assembly (3). Close front hood assembly. 3. Remove ten bolts (6) and the washers that hold rail assembly (5) to front hood assembly (3). Put lifting slings in position around rail assembly (5). Attach the lifting slings to a suitable lifting device. Remove rail assembly (5) from front hood assembly (3). The weight of rail assembly (5) is 25 kg (55 lb).4. Remove five bolts (7) and the washers that hold front hood assembly (3) to cowling assembly (8). 5. Install Tooling (A) on front hood assembly (3). Attach Tooling (A) to a suitable lifting device. Remove front hood assembly (3). The weight of front hood assembly (3) is 62 kg (136 lb). 6. Remove nut (10) that secures ground level shutdown switch (9) to cowling assembly (8). 7. Install Tooling (A) on cowling assembly (8). Attach Tooling (A) to a suitable lifting device.8. Remove ten bolts (11) and the washers that hold cowling assembly (8) to the frame assembly. Remove cowling assembly (8). The weight of cowling assembly (8) is 90 kg (198 lb). It is not necessary to purge the air conditioning system when removing the condenser from the radiator.9. Remove four bolts (12), the nuts and the washers that hold condenser assembly (13) to the plate. 10. Set condenser assembly (13) aside. Remove bolt (14) and the clips from the radiator group. 11. Remove the four bolts from each elbow (16) and (17). Disconnect two elbows (16) and (17) from radiator top tank assembly (15). Remove the gasket from each elbow (16) and (17).12. Remove four straps (18) that hold harness assembly (19). Set harness assembly (19) aside. 13. Install Tooling (A) on radiator top tank assembly (15). Attach Tooling (A) to a suitable lifting device.14. Remove 20 bolts (21) and (23) that hold five tube assemblies (22) to the radiator group. Four tube assemblies are located on the front side of radiator group, and one tube assembly is located on the rear side of radiator group.15. Mark and identify 20 bolts (20) for installation purposes. Remove 20 bolts (20) that fasten radiator top tank assembly (15) to the channel assemblies.16. Remove radiator top tank assembly (15) from the radiator core assemblies. The weight of radiator top tank assembly (15) is 92 kg (202 lb).17. Remove all of the end tank seals from the bottom of radiator top tank assembly (15). Some of the seals may stay on the radiator core assemblies. 18. Remove two bolts (24) and the washers from each of the radiator core assemblies that is to be removed.19. Remove the radiator core assembly from the bottom tank assembly. Remove end tank seal (25) from the radiator bottom tank assembly. The following steps are for the installation of the radiator cores (folded core). Check all seals for wear or damage, and replace if necessary. Replace all gaskets prior to installation. 20. Put end tank seal (25) in position on the radiator bottom tank assembly. Install each radiator core assembly in the radiator bottom tank assembly.21. For each radiator core assembly that was removed, install two bolts (24) and the washers. Do not tighten bolts (24) at this time. 22. Before tightening bolts (24), adjust gap (X) at the front of the radiator to a distance of 6.5 mm (0.25 in). Adjust gap (Y) at the rear of the radiator to a distance of 2.0 1.5 mm (0.08 0.06 in). The cores must not contact each other after assembly. Tighten bolts (24). 23. Place the end tank seals in position on top tank assembly (15).24. Install Tooling (A) to radiator top tank assembly (15). Attach Tooling (A) to a suitable lifting device.25. Put radiator top tank assembly (15) in position on the radiator core assemblies and the channel assemblies. Install 20 bolts (20) and the washers that hold radiator top tank assembly (15) to the channel assemblies.26. Put five tube assemblies (22) in position on the radiator group, and install 20 bolts (21) and (23) that hold tube assemblies (22) to the radiator group. 27. Put harness assembly (19) in position on the clips. Install four new straps (18) to hold harness assembly (19) to the radiator group.28. Put two elbows (16) and (17) and the gaskets in position on radiator top tank assembly (15). Install the four bolts that hold each elbow (16) and (17) to radiator top tank assembly. 29. Position condenser assembly (13) in position on the plates. Install four bolts (12) and the