3803771 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.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
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.
Put identification marks on all lines, hoses, wires, and tubes for installation purposes. Plug all lines, hoses and tubes. This helps prevent fluid loss and contamination of the water system.
Drain the coolant from the radiator. The capacity of the coolant system is 63 L (17 US gal) .
Open the engine hood.
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Loosen band clamp (10) that secures pipe (7) to hose (11) . Remove four reusable straps (3) from pipe (7) , ether hose (6) and overflow hose (12) .
Remove bolt (5) and the nut that secures pipe clamp (1) and the hose clamp together. Remove pipe clamp (1) from pipe (7) and ether hose (6) .
Remove bolt (2) and the nut that secures pipe clamp (8) to the mounting bracket. Remove pipe clamp (8) from the mounting bracket, pipe (7) and ether hose (6) .
Loosen band clamp (4) that secures pipe (7) in hose (9) . Remove pipe (7) from hose (9) and hose (11) .
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Remove nut (13) in order to disconnect ether hose (6) . Move the ether hose aside.
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Loosen band clamp (16) that secures hose (15) to shut off valve (14) . Move the hose and band clamp aside. Remove bolt (17) that secures mounting bracket (20) to water pump (19) . Disconnect the electrical connection on wire assembly (18) . Move wire assembly (18) and mounting bracket (20) aside.
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Remove bolt (21) from water pump (19) .
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Loosen band clamp (22) that secures hose (23) to water pump (19) . Disconnect the hose from the water pump.
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Remove bolt (24) that secures fan guard (25) to the radiator. Remove bolt (29) that secures fan guard (25) to the radiator.
Remove two bolts (27) that secure ether control (26) to the radiator. Remove bolt (28) and the wire clip from the radiator. Move ether control (26) aside.
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Remove bolt (30 ) that secures fan guard (25) to the radiator. Remove fan guard (25) from the radiator.
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Remove bolts (32) that secure water pump (19) to the engine. Remove water pump (19) , gasket (31) and the O-ring seal from the engine.
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Remove gasket (31) from water pump (19) . Remove O-ring seal (33)