3803829 Volvo.Penta Injection pump, exch

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, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
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 cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure 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 Coolant Additive contains alkali. Avoid contact with skin and eyes.
Position a suitable container under the radiator drain valves in order to contain the coolant for storage or disposal. Drain 132 L (35 US gal) of coolant from the radiator. Refer to Operation and Maintenance Manual, SEBU7176, "Cooling System Coolant (ELC) - Change" for the correct procedure.
Install caps and plugs on all openings in order to prevent dirt or debris from entering the system. Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
Raise the front hood assembly and the rear hood assembly.
Illustration 1 g00563653
Loosen clamp (3) that holds elbow assembly (2) to the exhaust elbow. Remove elbow assembly (2) and pipe assembly (1). Repeat this procedure for the remaining elbow assembly and pipe assembly.
Illustration 2 g00563655
Disconnect hose assembly (4) from union tee (5).
Illustration 3 g00563656
Disconnect hose assembly (6) from union tee (7).
Illustration 4 g00563657
Disconnect hose assembly (9) from union tee (8).
Illustration 5 g00563658
Position a suitable lifting device (not shown) to platform assembly (10). Secure the lifting device to a hoist. Remove four bolts (11) and the washers that hold platform assembly (10) to the engine. Remove platform assembly (10). The weight of platform assembly (10) is 53 kg (117 lb).
Illustration 6 g00563659
Remove two tube assemblies (12).
Illustration 7 g00563660
This is a view of the forward air inlet cover.
Disconnect hose assembly (13) from each of the air inlet elbows. Remove two bolts (14) and the washers that hold plate assembly (15) to the air inlet elbows. Place plate assembly (15) and hose assembly (13) aside as a unit.
Illustration 8 g00563661
This is a view of the rear air inlet cover.
Disconnect hose assembly (18) from each of the air inlet elbows. Remove two bolts (16), the plates, and the washers that hold plate assembly (17) to the air inlet elbows. Place plate assembly (17) and hose assembly (18) aside as a unit.
Illustration 9 g00563662
Remove remaining three bolts (20) that hold air inlet elbow (21) to air inlet cover (19). Remove two bolts (23), the plates, and the washers that hold elbow (22) to compressor cover (24). Remove air inlet elbow