3803695 Volvo.Penta Injection pump

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.
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.
Open the engine access door.
Release the hood latch on the radiator. This will allow access to the water temperature regulator.
Drain the coolant from the coolant system into a suitable container for proper storage or disposal.Note: The radiator is located at a higher level than the engine. It will be necessary to drain the radiator in order to replace the water temperature regulator.
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Remove five bolts (1). Remove pulley cover (2) .
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Remove two bolts (3). Remove water temperature regulator elbow (4) and move to the side.Note: The gasket on the water temperature regulator elbow may require some force to separate.
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Remove water temperature regulator (5) .Note: Visually check the configuration of the water temperature regulator for installation purposes. The water temperature regulator must be facing upward. The water temperature regulator will not operate properly unless the water temperature regulator is installed in the correct position.Note: Refer to the Operation and Maintenance Manual, SEBU7468 for information concerning the testing of the water temperature regulator.
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Remove gasket (6) under water temperature regulator elbow (4) .Note: Completely clean water temperature regulator elbow (4) prior to installation. Improper cleaning will cause leaks.Installation Procedure
Never operate an engine without water temperature regulators in the cooling system. Water temperature regulators help to maintain the engine coolant at the proper operating temperature. Cooling system problems can develop without water temperature regulators.
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Put water temperature regulator (5) in position in the water temperature regulator housing. The dome of the water temperature regulator (5) must be in the upper position.
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Install a new gasket (6) on water temperature regulator elbow (4) .
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Install water temperature regulator elbow (4). Secure water temperature regulator elbow (4) with two bolts (3). Tighten bolts to a torque of 22 N m (16 lb ft).
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Install pulley cover (2). Secure cover (2) with five bolts (1) .
Fill the radiator with coolant.Note: Refer to the Operation and Maintenance Manual, SEBU7468 for the proper type and the proper quantity of coolant.
Start the engine and check for coolant leaks. Fill the cooling system to the proper fluid level. Replace any fluid loss.
Lower the radiator.
Close the engine access door.