3803232 Volvo.Penta Injector

2. Put a suitable floor jack in position under step group (2) on the engine side of the machine. Fasten the step group to the floor jack.3. Remove four bolts (1) that hold step group (2) in position. Two bolts are located at the front of the step group. Two bolts are located at the rear of the step group.4. Carefully lower the step group, and remove it from the machine. the weight of the step group is 113 kg (250 lb).
View From Under Machine5. Remove eight hex head fasteners (4). Remove front cover (5) and rear cover (3) from under the engine.
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 in the cooling system. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
6. Release the pressure in the cooling system by slowly loosening the fill cap on the radiator.7. Drain the coolant from the cooling system into a suitable container for storage or disposal. The capacity of the cooling system is 35 liters (9.1 U.S. gal). 8. Loosen the two clamps, and remove upper radiator hose assembly (6). 9. Loosen the two clamps, and remove lower radiator hose assembly (7). 10. Shut off valve (9). Put identification marks on two hose assemblies (8) that are connected to the water separator for installation purposes. Disconnect the two hose assemblies from the water separator. 11. Remove bolt (12), the nut and clamp (13) from the mounting bracket. Put identification marks on the cable and wire that are connected to the rear of the alternator. Disconnect cable (10) and wire (11) from the alternator. 12. Remove the bolt and clamp (14). Disconnect electrical connector (15). 13. Remove bolt (17) the nut and clamp (16). Put identification marks on three cable assemblies (18) that are connected to the starter solenoid for installation purposes. Disconnect three cable assemblies (18). 14. Disconnect electrical connector (20). Remove bolt (19) and the washer. Remove cable assembly (21) from the electric starting motor. 15. For installation purposes, put identification marks on all hose assemblies (22) that are connected to the main hydraulic pump, the swing pump, and the swing charge pump. Disconnect the hose assemblies from the pumps. Put plugs in the ends of the hose assemblies to prevent oil loss and to keep contaminants out of the hydraulic system. 16. Loosen clamp (23), and disconnect hose assembly (24) at the water pump. 17. For installation purposes, put identification marks on four electrical connectors (25). Disconnect the four electrical connectors. 18. For installation purposes, put identification marks on three electrical connectors (26). Disconnect the three electrical connectors. 19. Remove bolt (27) and the washer that hold bracket (28) to the engine. Remove bracket (28) and wiring harness (29), as a unit, from the engine. 20. Remove two tie wraps (31). Disconnect two electrical connectors (30) from the governor cylinder. 21. For installation purposes, put identification marks on hose assemblies (32). Disconnect the two hose assemblies from governor cylinder (33). Put plugs in the ends of the hose assemblies to prevent oil loss and to keep contaminants out of the hydraulic system. 22. Disconnect hose assembly (35) from block (34). 23. For installation purposes, put identification marks on three hose assemblies (36) that are connected to the brake/pilot pump. Disconnect the three hose assemblies from the brake/pilot pump. Put plugs in the ends of the hose assemblies to prevent oil loss and to keep contaminants out of the hydraulic system. 24. Disconnect hose assembly (37) for the brake/pilot pump at firewall (38). 25. Remove tie wrap (40). Disconnect electrical connector (39) for the speed sensor. 26. Place a small wood block between engine enclosure support (41) and radiator (42). This will provide the necessary clearance between the fan assembly and the radiator for engine removal. 27. Fasten a hoist to the engine lifting brackets as shown.28. Remove four engine mounting bolts (43) that hold the engine to the frame of the machine.
Prior to removing the engine and main hydraulic pump from the machine, make sure all hose assemblies, tube assemblies and wires have been disconnected properly.
29. Carefully remove engine and main hydraulic pump (44), as a unit, from the machine. The combined weight of the engine and main hydraulic pump is 680 kg (1500 lb). 30. Remove two mounting bolts (45) and front engine mounting bracket (46). Remove the other front engine mounting bracket. 31. Remove two mounting bolts (47) and rear engine mounting bracket (48). Remove the other rear engine mounting bracket. The following steps are for the installation of the engine and main hydraulic pump.
Visually check the condition of the rubber mounts in the front and rear engine mounting brackets. If the rubber mounts are worn or damaged or appear to be compressed, use a new part for replacement.
32. Check the condition of all O-ring seals used in the ends of the hose assemblies and tube assemblies that connect at the engine or the main hydraulic pump. If any of the seals are damaged, use a new part for replacement. 33. Install two rear engine mounting brackets (48) and four mounting bolts (47). Tighten the four mounting bolts to a torque of 240 40 N m (175 30 lb ft). 34. Install two front engine mounting brackets (46) and four mounting bolts (45). Tighten the four mounting bolts to a torque of 240 40 N m (175 30 lb ft). 35. Fasten a hoist to engine and main hydraulic pump (44). Install four engine mounting bolts (43), but do not tighten the bolts at this time.36. Remove the small wood block between engine enclosure support (41) and radiator (42). Make sure the fan assembly on the engine is centered in the radiator shroud and no