3863398 Volvo.Penta Longblock

Table 1
Required Tools
Tool Part Number Part Description Qty
A 477-8634 Load Leveler Gp 1 Start By:
Remove the hood. Refer to "Hood - Remove and Install".
Remove the fan. Refer to "Fan - Remove and Install".
Remove the main hydraulic pump. Refer to "Main Hydraulic Pump - Remove and Install".
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 allow sufficient time for the cooling system to cool.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.
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, 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.
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 to help prevent fluid loss and keep contaminants from entering the system.
Recover the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating R134a for All Caterpillar Machines" for the recovery and the charging procedure. Refer to Special Publication, NENG2500, "Air Conditioning Tools" for the correct tools.
Drain the coolant into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual , "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedures.
Drain the engine oil into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual , "Engine Oil and Filter - Change" for the correct draining and filling procedures.
Illustration 1 g06548042
Turn the battery disconnect switch to OFF position.
Illustration 2 g06574858
Remove the cotter pin, pin (1), and gas spring assembly (2).
Illustration 3 g06574863
Loosen the clamp and remove hose (3). Loosen the clip and remove hose (4).
Loosen clamp (5), remove bolts (6), and hose (7).
Illustration 4 g06574866
Loosen clamp (9), remove bolt (8), and disconnect the hose.
Loosen clamp (10), remove bolt (11), and disconnect the hose.
Illustration 5 g06574881
Remove bango bolts (12) and disconnect hose assemblies (13).
Illustration 6 g06574883
Loosen nut (15) and disconnect shutoff cable assembly (14).
Loosen nuts (17) and disconnect governor motor assembly (16).
Illustration 7