877204 Volvo.Penta Gasket, decarbonizing

Start By:
Remove the transmission. Refer to Disassembly and Assembly, RENR5186, "Transmission - Remove".
Remove the expansion tank. Refer to Disassembly and Assembly, "Expansion Tank - Remove and Install".
Personal injury or death can result from improper lifting or blocking.When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component.Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.
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.
Put identification marks on all hoses, on all lines and on all wires for installation purposes. Plug all hoses and all lines. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
Illustration 1 g00983900
Pull back the terminal covers in order to disconnect positive cables (1) and negative cables (2) from batteries (3). Tie the cables onto the engine with a suitable cable strap as the cables are removed with the engine.
Illustration 2 g00983901
Loosen the hose clamps in order to disconnect two hoses (4) from fuel filter/water separator (5). Trace the hoses over the rear of the engine and remove all clamps or all cable straps that are attached. Make a note of the location of the clamps and straps for installation purposes.
Illustration 3 g00983902
Loosen the retaining nut in order to disconnect hose (6) from fuel filter (7). Trace the hoses over the rear of the engine and remove all clamps or all cable straps that are attached. Make a note of the location of the clamps and straps for installation purposes.
Illustration 4 g00983903
Remove pin (8) in order to disconnect cable (9) from the lever on fuel pump (10). Loosen two nuts (11) and remove the cable from bracket (12). Trace the cable over the engine and remove all cable straps and clips that secure the cable.
Illustration 5 g00983904
Disconnect electrical connector (13) for sensor (14) for the hydraulic oil filter from harness (15). Remove nut (16) and the washer in order to disconnect the harness from engine frame (17) .
Illustration 6 g00983908
Loosen the two hose clamps in order to disconnect heater hoses (18) from thermostat housing (19). Move the hoses aside.
Illustration 7 g00983909
Loosen the hose clamp in order to disconnect hose (20) from water pump (21). Disconnect hose (22) (if equipped) from accumulator (23) for the air conditioner.
Illustration 8 g00983910
Remove nut (24) and the washer in order to disconnect ground cable (25) from the engine frame (17). disconnect electrical connector (26) in order to disconnect harness (15) .
Illustration 9 g00983911
Remove nut (27) and the washer in order to disconnect the positive cable which is part of harness (15) from terminal block (28). The terminal block is located on the side of the chassis which is near to the exhaust muffler.
Illustration 10 g00983945