3803688 Volvo.Penta Injection pump

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     138-7573     Link Bracket     2    Start By:
Remove the engine enclosure. Refer to Disassembly and Assembly, "Engine Enclosure - Remove and Install".Note: Put identification marks on all hoses, on all hose 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 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.
At operating temperature, the engine coolant is hot and under pressure.Steam can cause personal injury.Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand.Remove the fill cap slowly to relieve pressure.Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
Drain the coolant from the cooling system into a suitable container for storage or disposal. The capacity of the cooling system is 16 L (4.2 US gal).
Illustration 1 g01020845
Loosen the hose clamp and disconnect hose (2) from the bottom of the radiator.
Disconnect the hose from the bottom of tube assembly (1) .
Remove the two bolts and clamp (3) from tube assembly (1).
Illustration 2 g01020847
Loosen the hose clamp and disconnect hose (5) from the top of radiator (4) .
Disconnect tube assembly (1) and remove the tube assembly from the radiator.
Illustration 3 g01020848
Attach Tooling (A) and a suitable lifting device. Remove eight bolts (6) that secure the radiator to the hydraulic oil cooler and remove the radiator. The weight of the radiator is approximately 35 kg (77 lb).Installation Procedure
Table 2
Required Tools    
Tool     Part Number     Part Description     Qty    
A     138-7573     Link Bracket     2    
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.
Illustration 4 g01020848
Attach Tooling (A) and a suitable lifting device. Install the radiator. The weight of the radiator is approximately 35 kg (77 lb). Position the radiator on the hydraulic oil cooler. Install eight bolts (6) .
Illustration 5 g01020847
Connect tube assembly (1) to the radiator.
Connect hose (5) to the top of radiator (4). Secure the hose with the hose clamp.
Illustration 6 g01020845
Position tube assembly (1). Install the two bolts and clamp (3) .
Connect the hose from the bottom of tube assembly (1) .
Connect hose (2) to the bottom of the radiator and tighten the hose clamp.