3863191 Volvo.Penta Kit

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     4C-4865     Hand Hydraulic Pump     1    
FT-1410 Sleeve     1    
6V-3160 Double Acting Cylinder     1    
6V-7742 Full Nut     2    
8T-3282 Hard Washer     2    
259-9239 Puller Stud     1    
B     260-0630     Link Bracket     2    
ZZ     9U-7081     Tapered Cap/Plug     2    
9U-7080 Tapered Cap/Plug     1    
9U-7071 Tapered Cap/Plug     1    
9U-7075 Tapered Cap/Plug     1    
6V-9508 Plug     1    
6V-9829 Cap As     1    Start By:
Remove the hood. Refer to Disassembly and Assembly, "Hood - Remove and Install".
Remove the engine side guards. Refer to Disassembly and Assembly, "Engine Side Guards - Remove and Install".
Remove the bottom guard. Refer to Disassembly and Assembly, "Bottom Guard - Remove".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.
Personal injury can result from contact with refrigerant.Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area.Personal injury or death can result from inhaling refrigerant through a lit cigarette.Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death.Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.
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, "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.
Note: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.
Drain the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".
Recover the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant". Refer to Special Publication, NEDG5065, "Air Conditioning Tool".
Illustration 1 g01125639
Remove bolts (1) . Remove plate assembly (2) .
Illustration 2 g01125641
Disconnect hose assembly (3) .
Loosen clamp (5) and disconnect hose (4) .
Disconnect harness assemblies (6) . Remove bolt (7) .
Illustration 3 g01125645
Loosen clamp (9) . Disconnect hose (8) .
Illustration 4 g01125648
Loosen clamp (11) . Disconnect hose (10) . Loosen clamp (13) . Disconnect hose (12) .
Disconnect hose assembly (14) . Remove bolt (15) . Disconnect hose assembly (16) .
Illustration 5 g01125653
Illustration 6 g01125652