20795923 Volvo.Penta Plug

START BY:a. remove hoodb. remove fan guard1. Drain the coolant from the cooling system. 2. Loosen hose clamps (1), and disconnect hose (2) and tube (3) as a unit from the radiator. Turn inlet tube (3) in the lower hose to provide clearance when the radiator cores are removed. 3. Remove strip (8) and baffle assembly (7).4. Remove nut (4) that holds strip (9) and the baffle in place.5. Remove seven bolts (6) that hold upper left hand shield assembly (5). 6. Pull strip (9) and the baffle away from stud (10) so that shield assembly (5) can be removed. Remove upper left hand shield assembly (5) from the machine.7. Repeat steps 4 through 6 to remove upper right hand shield assembly (11). 8. Remove bolts (13) from under the flange of the top tank, and remove upper baffle assembly (12). 9. Disconnect overflow hose (16) from the radiator.10. Remove eight bolts (14) that hold top tank (15) in place.11. Fasten tooling (A) and a hoist to the top tank as shown.12. Remove top tank (15) from the radiator. The weight of the top tank is 24 kg (54 lb.). 13. Remove two bolts (18) that hold radiator core (17) to two tie straps (19) (one on each side of the radiator core.14. Loosen the other two bolts (20) that hold the other end of two tie straps (19), and move them out of the way to provide clearance when radiator core (17) is removed. Remove radiator core (17) from the radiator assembly.15. Repeat steps 14 and 15 to remove the other radiator cores.
Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping Freon-12 (C C12 F2 Dichloro Difluoro Methane) can cause freezing of human flesh.Do not smoke while working on air conditioning systems. Inhaling Freon-12 through any smoking material, although not toxic or flammable, can generate phosgene gas and cause violent illness. Also, heat must never be applied to a charged system. See Air Conditioning And Heating Service Manual, Form No. SENR7454, for more information on removal and installation of lines and refrigerant from the system.
16. If the machine is equipped with air conditioning, perform the following steps to remove air conditioning cores (24) and (25) from the radiator assembly.a. Loosen two couplings (21), and disconnect hose assembly (22) and (23) to prevent the excessive loss of Freon from the system.b. Disconnect hose assembly (24) and tube assembly (27) from air conditioning core (26).c. Remove two bolts (20) that hold air conditioning core (26) to two tie straps (19) (one on each side of the radiator core).d. Loosen the other two bolts (18) that hold the other end of two tie straps (19), and move them out of the way to provide clearance when the air conditioning core (26) is removed. Remove air conditioning core (26) from the radiator assembly.e. Disconnect hose assembly (24) and the other tube assembly from the bottom of air conditioning core (25).f. Repeat steps c and d to remove air conditioning core (25) from the radiator assembly. 17. Remove seal (28) from each end of the radiator cores and/or the air conditioning cores.Install Radiator And Air Conditioning Cores (Folded Core)
1. Make sure the radiator cores and the holes in the bottom tank are clean and free of dirt and foreign material.2. Lightly lubricate the inside diameter of the seals and the sealing surface of the seals, the bottom tank and the radiator cores with liquid soap. There are two different seals used in the installation of the radiator cores. The distance between the locating projections on each end of the radiator and air conditioning cores is different. Install the correct seal on each end of the cores. 3. Install the correct seals (1) on radiator core (2).4. Put radiator core (2) in position on the bottom tank with locating projections (4) aligned with locating holes (3) in the bottom tank. 5. Put two straps (6) in position on the radiator core, and install bolts (5) that hold them in place.