3803282 Volvo.Penta Injector, exch

start by:a) remove hood1. Drain the coolant from the cooling system. Drain the oil from the hydraulic tank. 2. Remove elbows (1) and (2) from the radiator top tank and cylinder head. 3. Remove bolts (4) and remove panel assemblies (3) from each side of the machine. 4. Remove the bolt that holds the clamp for tube (7) to the radiator guard.5. Remove plates (5) and (6). Disconnect the upper end of tube (7) from the hydraulic oil cooler. 6. Loosen the clamp for the hose on the end of tube (7). Remove the bolt that holds clamp (8) to the radiator guard and remove tube (7).7. Remove bolts (10) and plates (9). Disconnect tube (11) from the hydraulic oil cooler. Loosen the hose clamp and remove tube (11). 8. Remove fan guard assembly (12) from the machine. 9. Loosen hose clamp (13). Remove the bolts that hold elbow (14) to the radiator and remove elbow (14) and the gasket. 10. Remove bolts (15), the washers and nuts from each side of the machine. 11. Remove guards (16) and (17) from the machine. 12. Disconnect wire (20) from horn (18). Remove bolts (19) and remove horn (18) from the machine. 13. Remove the nut and clip (22) from around the wiring harness.14. Disconnect the wiring harness for the lights at connection (21) and pull the lower wiring harness from the radiator guard.15. Remove baffle assembly (23) from the left side of the radiator guard.16. Remove baffle assembly (24) from the right side of the radiator guard. 17. Remove pin (25) from the machine. 18. Use tools (A) and fasten a hoist to the radiator and guard. Remove bolts (26) from both sides of the machine and remove the radiator and guard. The weight of the radiator and guard is 800 lb. (365 kg).Install Radiator And Guard (Later)
1. Fasten a hoist to the radiator and guard with tools (A). Put the unit in position and install the bolts to hold it to the frame. Tighten the bolts to a torque of 265 35 lb.ft. (360 47 N m). 2. Install draw bar pin (1).3. Install baffle assembly (2) on the right side of the machine. 4. Connect the main wiring harness to the wiring harness for the lights at connection (5). Install clip (3) to hold the wiring harness in position.5. Install baffle assembly (4) on the left side of the machine. 6. Put horn (6) in position and install the bolts to hold it. Connect wire assembly (7) to the horn. 7. Install guards (8) and (9) on the radiator guard. 8. Install bolts (11), the nuts and washers on each side of the machine.9. Make sure the O-ring seal is installed in the end of tube (12) and put clean hydraulic oil on it. Put tube (12) in position and connect it to the lower end of the hydraulic oil cooler with flanges (10). 10. Install guard assembly (13) over the fan. 11. Make sure the O-ring seal is installed in the end of tube (14) and put clean hydraulic oil on it. Put tube (14) in position and connect it to the upper end of the hydraulic oil cooler with the flange and bolts. 12. Install the four plates (15) on the shield assemblies over tubes (12) and (14).13. Put hoses (16) and (17) on tubes (12) and (14) and tighten the clamps. 14. Install the gasket and elbow (19) on the lower radiator tank. Move the water pump hose into position and tighten clamps (18). 15. Install the gaskets, elbows (20) and (21) and the hose to connect the radiator top tank to the cylinder head. 16. Install panel assemblies (22) on each side of the machine.17. Fill the cooling system with coolant to the correct level. Fill the hydraulic tank with oil to the correct level.end by:a) install hood