866882 Volvo.Penta Injector

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     1U-9200     Lever Puller Hoist     1    
B     138-7575     Link Bracket     2    
ZZ     9U-7086     Tapered Cap     1    
9U-7090 Tapered Cap     1    
9U-7091 Tapered Cap     4    
9U-7092 Tapered Cap     1    
6V-7494 Tapered Cap     1    
6V-9511 Face Seal Plug     4    
6V-9832 Cap As     4    
6V-9513 Plug     2    
6V-9834 Cap As     2    Start By:
Remove the engine enclosure. Refer to Disassembly and Assembly, "Engine Enclosure - Remove and Install".
Remove the bottom guards. Refer to Disassembly and Assembly, "Bottom Guards - Remove and Install".Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.
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, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Personal injury can result from hydraulic oil pressure and hot oil.Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.
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.Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
Turn the battery disconnect switch to the OFF position.
Drain the cooling system. Refer to Operation and Maintenance Manual for the correct procedure.
Illustration 1 g01018455
Disconnect cable assembly (4) from battery (1). Remove clips (2) and (3) in order to disconnect cable assembly (4) .
Illustration 2 g01007792
Illustration 3 g01018454
Remove bolts (6) and (5) in order to disconnect cable assembly (7) .
Cut four cable straps (9) and position harness assemblies (8) out of the way.
Illustration 4 g01007796
Disconnect hose assemblies (10) .
Illustration 5 g01007797
Remove nuts (11) and bolts (13) i