3828439 Volvo.Penta Injection pump

At operating temperatures, the oil tank is hot and under pressure. Hot oil can cause burns. Remove the fill plug only when the engine is stopped and when the fill plug is cool enough to touch with your bare hands.
1. Release the pressure in the hydraulic system by slowly loosening the fill cap located on top of the hydraulic oil tank.2. Drain the hydraulic oil from the fuel/hydraulic oil tank. The capacity of the hydraulic oil portion of the tank is 55 liters (14.5 U.S gallons).
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 from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
3. Release the pressure in the cooling system by slowly loosening the fill cap on the radiator.4. Drain the coolant from the cooling system. The capacity of the cooling system is 25.7 liters (6.8 U.S. gallons). 5. Turn the disconnect switch to the OFF position.6. Mark or identify the cable assemblies for installation purposes. Disconnect cable assemblies (2) from the quick start post.7. Mark or identify the cable assemblies for installation purposes. Disconnect the cable assemblies from disconnect switch (3).8. Remove the four bolts from each brace, and remove braces (1) from the machine. 9. Close fuel shut-off valves (4). Disconnect fuel lines (5) from the shut-off valves. Cap and plug immediately. 10. Remove the two screws, and separate electrical connector (6). Disconnect electrical connector (7). 11. Remove the nut that fastens ground wire (8) to the frame. Disconnect electrical connectors (9). Remove all the cable ties that hold the wiring harnesses to the frame. 12. Put identification marks on wires (10) for installation purposes. Disconnect the two wires from the fuel level sending switch. Remove cable ties (11) that fasten the wiring harness to the fuel/hydraulic oil tank and to the frame. Move the wiring harness out of the way. 13. Put identification marks on two wires (12) for installation purposes. Disconnect the two wires from the hydraulic oil temperature switch.14. Remove the two bolts that fasten two relay switches (13) to the frame. Remove all the cable ties that fasten the harness assembly to the frame. Move the wiring harness out of the way. 15. Disconnect three hose assemblies (14) from the steering pump. Cap and plug immediately. 16. Mark or identify the cable assemblies for installation purposes. Disconnect cable assembly (15) from the starter. Remove the two bolts and clips that hold the cable assembly in place, and move the cable assembly out of the way. Disconnect cable assembly (ground) (16) from the starter. 17. Disconnect hose assemblies (17) from the hydraulic oil tank. Cap and plug immediately.18. Mark for identification and disconnect the 11 hose assemblies from brake/shift valve (18). Cap and plug immediately.19. Mark for identification and disconnect the five hose assemblies from vibratory cooling/control valve (21). Cap and plug immediately.20. Mark for identification and disconnect the three hose assemblies from vibratory pump (22). Cap and plug immediately.21. Mark for identification and disconnect the eight hose assemblies from propel pump (20). Cap and plug immediately.22. Remove the two bolts that fasten bracket (19) to the engine. Move the bracket and hose assemblies out of the way. 23. Remove the seven bolts, and remove fan guard (23) from the shroud.24. Remove the three nuts and bolts that hold the engine to the frame of the machine.25. Attach a hoist to engine (24) as shown. Make sure all the necessary hose assemblies and electrical wires have been disconnected. Carefully remove the engine, radiator and pumps as a unit from the machine. The weight of the engine, radiator and pump as a unit is 840 kg (1850 lb). After the engine has been installed, fill the cooling system with coolant to the correct level. Fill the hydraulic oil tank to the correct level. See the Operation & Maintenance Manual for the correct filling procedures. For installation of the engine, reverse the removal steps.