3860243 Volvo.Penta Gear, lower

Table 1
Required Tools
Tool Part Number Part Description Qty
A 237-9608 Mounting Bar 2
B 376-8697 Guide Stud
5/8 - 11 by 36 inch
(1) 2
8T-4122 Hard Washer 4
6V-4803 Thrust Bearing 4
4K-0367 Full Nut 8
C - Loctite Graphite Anti-Seize -
F 221-8647 Seal Installer Gp 1
G - 2-7/8 inch Vented Plug 1
- 2-3/4 inch Vented Plug 1
- 2-1/8 inch Vented Plug
(2) 2
- 1-7/8 inch Vented Plug
(3) 2
5P-3501 Adapter 2
3J-1907 O-Ring Seal 2
2D-7325 Pipe Tee 2
8T-0853 Pressure Gauge 2
4C-7121 Pipe Nipple 2
4C-7090 Valve 2
4C-7158 Fitting 2
(1) Cut 376-8697 guide studs to 18 inch lengths. Four 18 inch guide studs are required.
(2) Use with 201-6758 Sea Water Heat Exchanger Gp.
(3) Use with 290-3990 Sea Water Heat Exchanger Gp.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Check the O-ring seals and the seals for wear or for damage. Replace the components, if necessary.
Illustration 1 g02718886
Install hose connector (16) on filler neck (17). Install O-ring seal (18) on the filler neck.
Position filler neck (17) on the frame assembly. Install bolts (15).
Install pressure cap (14).
Illustration 2 g02718864
Use Tooling (F) to install lip seal (13) in the frame assembly.
Illustration 3 g02718840
Install inserts (12).
Install elbows (10) and zinc rods (11). Ensure that elbows (10) are in the proper orientation.
Install seals (9) in elbows (10).
Install Tooling (B) and Tooling (A) in the frame assembly. Ensure that Tooling (B) and Tooling (A) are securely installed. Apply Tooling (C) to the threads of the nut and the threads of the guide stud prior to installation.
Illustration 4 g02145556
Position the new seal on the heat exchanger plate. Install tabs (X) of the seal into the slots of heat exchanger plate (8).Note: Use a new seal on the heat exchanger plates for the fuel.
Illustration 5 g06015845Note: Type 1 heat exchangerNote: Do not reuse the old gasket.Note: Heat Exchanger Plate (Y) and Heat Exchanger Plate (Z) are identical. The orientation of the dimple (one dimple) on the heat exchanger plate is critical during the assembly of the heat exchanger plates. Heat Exchanger Plate (Y) and Heat Exchanger Plate (Z) are for the jacket water in the heat exchanger.Note: Heat Exchanger Plate (S) and Heat Exchanger Plate (T) are identical. The orientation of the dimples (two dimples) on the heat exchanger plate is critical during the assembly of the heat exchanger plates. Heat Exchanger Plate (S) and Heat Exchanger Plate (T) are for the fuel cooler in the heat exchanger.Note: Heat Exchanger Plate (W) has a notch that is stamped in the heat exchanger plate. The notch identifies the port that is blocked to prevent coolant flow. Heat Exchanger Plate (W) is installed to separate the jacket water from the fuel. The orientation of the notch and dimples (two dimples) on the heat exchanger plate is critical during the assembly of the heat exchanger plates.Note: Heat Exchanger Plate (P) has a notch that is stamped in the heat exchanger plate. The notch identifies the port that is blocked to prevent coolant flow. Heat Exchanger Plate (P) is installed against the front frame. The orientation of the notch and dimples (two dimples) on the heat exchanger plate is critical during the assembly of the heat excha