3812105 Volvo.Penta Plug

Table 1
Required Tools
Tool Part Number Part Description Qty
A 439-3938 Link Bracket 2
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.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
Illustration 1 g01238471
Remove bolts (1) and the retainers. Remove air pipes (2). Remove the O-ring seals from the air pipes.
If necessary, remove bolts (5) and remove adapters (4). Remove the O-ring seals from the adapters.
Attach Tooling (A) and a suitable lifting device to the top of air inlet cover (3). The weight of air inlet cover (3) is approximately 35 kg (77 lb).
Remove bolts (6). Remove air inlet cover (3).Note: Be careful not to damage the fins of the aftercooler core.
Illustration 2 g01238477
Disconnect tube assembly (7) and tube assembly (8). Remove the O-ring seals from the tube assemblies.
Attach a suitable lifting device onto aftercooler core (9). The weight of the 3508C aftercooler core is approximately 60 kg (132 lb). The weight of the 3512C aftercooler core is approximately 85 kg (187 lb). Remove aftercooler core (9) from the air inlet manifold. Remove seals (10) from aftercooler core (9).Note: Be careful not to damage the fins of the aftercooler core.Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 439-3938 Link Bracket 2
B 369-9450 Petro Amber Gel -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Be careful not to damage the fins of the aftercooler cores.
Illustration 3 g01238477
Install seal (10) on the bottom of aftercooler core (9). Temporarily secure the bottom seal with tape. Make sure that the tape can be removed after the aftercooler core is installed. Do not use an adhesive, a silicone lubricant, or any other lubricant for retention of the seal.
Attach a suitable lifting device onto aftercooler core (9). The weight of the 3508C aftercooler core is approximately 60 kg (132 lb). The weight of the 3512C aftercooler core is approximately 85 kg (187 lb). Position aftercooler core (9) onto the air inlet manifold. Ensure that the bottom seal is properly seated.
Install seal (10) on top of the aftercooler core.
Install the O-ring seal on tube assembly (8). Lubricate the O-ring seal with Tooling (B). Connect tube assembly (8) to aftercooler core (9).
Install the O-ring seal on tube assembly (7). Lubricate the O-ring seal with Tooling (B). Connect tube assembly (7) to aftercooler core (9).
Illustration 4 g01238471
Illustration 5 g01238547
Attach Tooling (A) and a suitable lifting device to the top of air inlet cover (3). The weight of air inlet cover (3) is approximately 35 kg (77 lb).
Position air inlet cover (3) onto the aftercooler core. Ensure that the seal is seated between air inlet cover (3) and the aftercooler core.
Install bolts (6). Hand tighten bolts (6) to the following procedure:
Tighten the bolts in the numerical sequence to a torque of 24 N m (18 lb ft).
Tighten the bolts in the numerical sequence to a torque of 47 N m (35 lb ft).
Remove the tape that secured the bottom seal.
Install the O-ring seals on adapters (4). Position adapters (4) on the cover and install bolts (5).
Install the O-ring seals on air pipes (2). Lubricate the O-ring seals with Tooling (B). Install air pipes (2) and install the retainers and bolts (1).
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".