860513 Volvo.Penta Injection pump

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 drain valve for the left side of the radiator in order to contain the coolant for storage or disposal. Drain the coolant below the level of the expansion tank. The capacity of the right side of the radiator is 397 L (105 US gal).
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.
Illustration 1 g00580944
Remove bolt (3), the washer, and the clip that holds tube assembly (2) to the engine. Remove tube assembly (2) from elbow (1) and the bonnet (not shown).
Illustration 2 g00582763
Remove tube assembly (4) from bonnet (5) and bonnet (6).
Illustration 3 g00580946
Remove four bolts (8) that hold adapter (9) to engine oil cooler (7).
Illustration 4 g00580948
Position a suitable lifting sling around engine oil cooler (7). Secure the lifting sling to a hoist.
Remove four bolts (11) and the washers that hold screen assembly (10) to oil cooler core (12). Place screen assembly (10) aside in order to remove engine oil cooler (7).
Illustration 5 g00580949
Remove six bolts (14) that hold engine oil cooler (7) to bonnet (13).
Illustration 6 g00580951
Remove two bolts (16) and the washers that hold bonnet (13) to bracket (15).
Illustration 7 g00580952
Put identification marks on four bolts (20) that hold flange (19) to adapter (17). Remove four bolts (20) and the washers that hold flange (19) to adapter (17). Remove bonnet (13), tube (20), flange (19), and gasket (18) (not shown) from adapter (17) as a unit.
Illustration 8 g00580954
Put identification marks on eight bolts (22) that hold engine oil cooler (7) to bonnet (6). Remove eight bolts (22) that hold engine oil cooler (7) to bonnet (6). Remove gasket (23) (not shown) from bonnet (6).
Illustration 9 g00580955
Remove two bolts (24) that hold bonnet (6) to the engine in order to loosen bonnet (6). Remove engine oil cooler (7) from bonnet (6). The weight of engine oil cooler (7) is 48 kg (105 lb).
Illustration 10 g00580957
Remove O-ring seal (25) from adapter (9).