856555 Volvo.Penta Expansion plug

Table 1
Required Tool    
Tool     Part Number     Part Description     Qty    
A     138-7573     Link Bracket     2    
B     1U-9200     Lever Puller Hoist     1    
C     8T-5255     Hydraulic Jack     1    Start By:
Remove the cooling package. Refer to Disassembly and Assembly, "Cooling System Package (Radiator, Aftercooler, Oil Cooler) - Remove".
Remove the middle bottom guard. Refer to Disassembly and Assembly, "Bottom Guards - Remove".Note: Put identification marks on all hoses, on all hose assemblies, on all harness assemblies, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.
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 Dealer Service Tool Catalog" 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 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.
Drain the fuel from the fuel tank into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Fuel Tank Water and Sediment - Drain".
Recover the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure. Refer to Dealer Service Tool Catalog, NENG2500, "Air Conditioning Tools" for the correct tools.
Illustration 1 g01317966
Disconnect harness assemblies (2) and push harness assemblies (2) through hood support (1) .
Illustration 2 g01317979
Disconnect harness assembly (3) . Remove ether cylinder mounting (4) . Remove bolt (5) .
Illustration 3 g01317996
Remove cable straps (6) .
Illustration 4 g01318014
Disconnect hose (9) . Loosen clamp (8) . Disconnect hose (7) .
Illustration 5 g01318122
Attach Tooling (A) and a suitable lifting device to hood support (10) . Remove hood support (10) and the air cleaner assembly at the same time. The weight of hood support (10) and the air cleaner assembly is approximately 45 kg (100 lb).
Illustration 6 g01318183
Right side of the machine
Illustration 7 g01318188
Left side of the machine
Remove cover assemblies (11) .