3803696 Volvo.Penta Injection pump

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     178-3704     Lifting Bracket As     1    Start By:
Remove the hood. Refer to Disassembly and Assembly, "Hood - Remove".
Remove the radiator tank. Refer to Disassembly and Assembly, "Radiator Tank - Remove and Install".Note: Put identification marks on all hoses, on all hose assemblies, on all wires, 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.Note: Cleanliness is an important factor. Before you begin the removal procedure, the exterior of the components should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
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 Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g01098856
Remove bolts (1) . Disconnect clip (2) . Position condenser (3) out of the way on the left track.
Illustration 2 g01262946
Illustration 3 g01098857
Disconnect hoses (4) .
Attach Tooling (A) to radiator core (6) , as shown. The weight of radiator core (6) is approximately 25 kg (55 lb).
Remove bolts (5) , bolts (7) , and radiator core (6) . Remove the seal (not shown) for the radiator core.Installation Procedure
Table 2
Required Tools    
Tool     Part Number     Part Description     Qty    
B     207-1601     Rubber Lubricant     1    
207-1600 (1) Rubber Lubricant     1    
( 1 ) For EAME OnlyNote: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.
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 Dealer Service Tool Catalog" 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 g01262946
Illustration 5 g01098857
Inspect the rubber seal. Apply Tooling (B) to the seal before installing the radiator core. Do not use a petroleum based lubricant on the seal. Refer to Special Instruction, REHS1063. Note: Soap may be used to lubricate the seal if the soap does not contain abrasive additives or chlorine.
Use Tooling (A) and a suitable lifting device in order to position radiator core (6) on the machine. The weight of radiator core (6) is approximately 25 kg (55 lb).
Install bolts (5) and (7) . Connect hoses (4) .
Illustration 6 g01098856
Position condenser (3) . Install bolts (1) . Connect clip (2) .End By:
Install the radiator tank. Refer to Disassembly and Assembly, "Radiator Tank - Remove and Install".
Install the hood. Refer to Disassembly and Assembly, "Hood - Install".