3827752 Volvo.Penta Overhaul kit, turbo

At operating temperature, the steering and brake hydraulic oil tank is hot and under pressure. Hot oil can cause burns.To prevent possible personal injury, release the pressure in the steering and brake hydraulic system before hydraulic lines or components are disconnected or removed.
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 cooling system pressure cap is cool enough to touch with your bare hand.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.
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.
To prevent dirt and contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected.This action also lessens the chance of oil spills.
Park the machine on a hard, level surface. Engage the parking brake and chock the wheels. Turn the disconnect switch to the OFF position.
Put identification marks on all lines, hoses, wires and tubes for installation purposes. Plug all lines, hoses and tubes. This helps prevent fluid loss and contamination of the fluid system.
Drain the coolant into an appropriate container. The capacity of the cooling system is 53 L (14 US gal).
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Remove four bolts (1) and the nuts on the exhaust pipe assembly.
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Remove two bolts (2), the washers and the nuts that secure the exhaust pipe to the exhaust support bracket.
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The turbocharger shield has been removed for photographic clarity.
Remove clamp (3) that secures the exhaust pipe to the turbocharger and remove the exhaust pipe.
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The fuel tank has been removed for photographic clarity.
Remove drain plug (4) and drain brake oil cooler (5) into an appropriate container. Remove the washer from the drain plug.
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The fuel tank has been removed for photographic clarity.
Remove eight bolts (6), the washers and four half clamps (7) that secure two brake lines (8) to the brake oil cooler. Remove the two O-rings that seal the brake lines to the brake oil cooler.
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The fuel tank has been removed for photographic clarity.
Remove three bolts (9) and the washers that secure brake oil cooler (5) to the engine.
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Attach lifting straps and a hoist to brake oil cooler (5).
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Remove six bolts (10) that secure brake oil cooler (5) to bonnet (11). Remove the brake oil cooler from the machine. The weight of the brake oil cooler is 27 kg (60 lb).