3838861 Volvo.Penta Gasket

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     138-7575     Link Bracket     2    
ZZ     9U-7081     Cap Assembly     2    
6V-9508 Face seal Plug     1    
6V-9829 Cap Assembly     1    
6V-9509 Face seal Plug     1    
6V-9830 Cap Assembly     1    
6V-9513 Face seal Plug     1    
6V-9834 Cap Assembly     1    
9U-7080 Cap Assembly     1    
9U-7084 Cap Assembly     1    
6V-9832 Cap Assembly     2    
6V-9511 Face seal Plug     2    
9U-7089 Cap Assembly     1    Start By:
Remove the hood. Refer to Disassembly and Assembly, "Hood - Remove".
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.Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.
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.
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.
Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.Note: Put identification marks on all lines, hoses, wires, and tubes for installation purposes. Plug all lines, hoses and tubes. This helps prevent fluid loss and contamination of the fluid systems.
Drain the coolant from the machine into a suitable container. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change". The capacity of the radiator is approximately 30 L (8 US gal).
Drain the hydraulic oil from the machine into a suitable container. The capacity of the hydraulic tank is approximately 57 L (15 US gal).
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.
Recover the air conditioner refrigerant from the air conditioner system. The correct charge is 0.8 kg (1.8 lb). Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure.
Put identification marks on all hoses, on all tubes and on all wires for installation purposes. Plug all hoses and tubes. This helps prevent fluid loss, and this helps to keep contaminants from entering the system.
Illustration 1 g01080665
Remove fan guard (1) .
Illustration 2 g01080671
Remove bolt (2) and position bracket (3) aside.