3803702 Volvo.Penta Injection pump

Start By:
Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. 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 in Caterpillar machines.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.
Personal injury can result from hydraulic oil pressure and hot oil.Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.
Note: Put identification on all lines, hoses, wires, and tubes for installation purposes. Use caps and plugs on all lines, hoses, and tubes in order to prevent fluid loss or contamination of the systems.
Open the engine hood. The water pump is located on the right side of the machine.
Drain the radiator. The capacity of the cooling system is 43 L (11.4 US gal).
Illustration 1 g00466470
Loosen two hose clamps which hold upper radiator hose (1) in place. Remove upper radiator hose (1) .
Remove the three bolts which hold the support bars (2) and (3) in place. Remove support bars (2) and (3) .
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Disconnect three hydraulic hoses (4) which attach to the fan motor.
Remove seven bolts (5) .
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Disconnect the electrical connectors which attach to electrical panel (6) .
Remove the two bolts which hold air filter indicator (7) in place.
Disconnect oil tube (11) for the high speed arrangement from shield assembly (13) .
Disconnect hydraulic hose (10) from shield assembly (13) .
Remove tube (8) for the engine oil filler. Remove tube (9) for the engine oil dipstick.
Remove bolt (12) which supports shield assembly (13) .
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Remove four bolts (14) which hold the electrical panel in place.
Disconnect four grease fittings (15) from shield assembly (13) .
Remove bolt (16) which supports shield assembly (13) .
Carefully remove shield assembly (13) from the machine.
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Remove two bolts (17) .
Loosen the clamp which holds hose (19). Disconnect hose (19) .
Remove four bolts (18) .
Remove water pump (20) .Installation Procedure
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Install water pump (20) .
Install four bolts (18) .
Connect hose (19) and tighten the hose clamp.
Install two bolts (17) .
Illustration 7 g00467401
Carefully install shield assembly (13) on the machine.
Install bolt (16) which supports shield assembly (13) .
Connect four grease fittings (15) to shield assembly (13) .
Install four bolts (14) which hold the electrical panel in place.