3803687 Volvo.Penta Injection pump, exch

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
ZZ     6V-9507     Face Seal Plug     4    
6V-9828 Cap As     4    Start By:
Release the hydraulic system oil pressure. For additional information, refer to Disassembly and Assembly, "System Pressure - Relase".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.
Cylinders equipped with lock valves can remain pressurized for very long periods of time, even with the hoses removed.Failure to relieve pressure before removing a lock valve or disassembling a cylinder can result in personal injury or death.Ensure all pressure is relieved before removing a lock valve or disassembling a cylinder.
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: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.Pump and Motor Group
Open the hood. For additional information, refer to Operation and Maintenance Manual, "Hood Tilt".
Deactivate the electrical system. Refer to Operation and Maintenance Manual, "Battery Disconnect Switch" in order to deactivate the electrical system.
Illustration 1 g01015944
Remove bolts (1) from the circuit breaker panel. Remove the circuit breaker panel.
Illustration 2 g01015945
Remove clamp (2) and disconnect cable assembly (3) from the circuit breaker panel.
Illustration 3 g01015946
Remove clamp (4) that is securing the hose assembly (not shown) for the air conditioning from the back of panel assembly (5). Remove bolts (6) that secure panel assembly (5) and lower panel assembly (5) .
Illustration 4 g01015947
Remove clips (11) and cable assembly (8). Disconnect harness assembly (9). Label hose assemblies (7) and (10) for the pump and the motor. Remove hose assemblies (7) and (10) from the side of the pump and motor group.
Illustration 5 g01015948
Remove four mounting bolts (12) from the pump and the motor (13). Two bolts are located on each side of pump and motor group (13). Remove the pump and motor group (13) .Hood Tilt Cylinder
Open the engine hood. Do not allow the hood tilt cylinder to extend all the way. Attach a chain around the engine hood, as shown. This will support the engine hood when the hood tilt cylinder is removed.
Illustration 6 g01021859
Illustration 7 g01021860
Attach one end of a chain to the lifting eye of the engine hood. Place the chain over the engine hood and attach the other end of the chain to the lifting eye of the engine, as shown.
Illustration 8 g01021861
Lower the engine hood until tension is on the chain. Disconnect hose assemblies (4) and (5) from the hood ti