3860880 Volvo.Penta Pump

Table 1
Required Tools
Tool Part Number Part Description Qty
A 473-2944 Capping Kit 1
B - De-ionized Water 1
Ensure that all adjustments and repairs that are carried out to the Diesel Emission Fluid (DEF) system are performed by authorized personnel that have the correct training.Before beginning ANY work on the DEF system, refer to Operation and Maintenance Manual, "General Hazard" for safety information.
Care must be taken to ensure that Diesel Emission Fluid (DEF) for the system 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.Dispose of all fluids according to local regulations and mandates.
Ensure that the purge process for the DEF system is completed before turning the battery disconnect switch to the OFF position. Refer to the Operation and Maintenance Manual, "Battery Disconnect Switch" for further information.
Refer to the Original Equipment Manufacture (OEM) for the location of the diesel exhaust fluid tank.
Drain the coolant from the cooling system to a level below the solenoid valve, into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure.
Illustration 1 g03732064
Typical example
Ensure that the area around manifold DEF heater (3) is clean and free dirt and debris. If necessary, clean the area around the manifold DEF heater. If necessary, clean the area around the manifold DEF heater. Clean the area around the manifold DEF heater with Tooling (B) and a suitable tool.
Make temporary mark on cable straps (13) for installation purposes. Cut the cable straps from the harness assemblies and the diesel emission fluid lines.
Disconnect the Original Equipment Manufacture (OEM) harness assemblies from harness assembly (5), harness assembly (11), and harness assembly (14). Use Tooling (A) to cap the harness assemblies.
Remove diesel emission fluid line (7) and diesel emission fluid line (6) from manifold DEF heater (3). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.
Loosen the hose clamps and disconnect the hose assembly (8) and hose assembly (9) from manifold DEF heater (3). Use Tooling (A) to cap hose assemblies and the manifold DEF heater.
Remove bolt (4) and bolt (12) for strap (2) and strap (10). Remove the straps from diesel exhaust fluid tank (1).
Remove diesel exhaust fluid tank (1) from the mounting bracket. Installation Procedure
Ensure that all components are free from wear or damage. Replace any component that is worn or damaged.
Illustration 2 g03732064
Typical example
Install diesel exhaust fluid tank (1) onto the mounting bracket.
Install strap (2) and strap (10) onto diesel exhaust fluid tank (1). Ensure that the straps are correctly installed onto the diesel exhaust fluid tank.
Install bolt (4) and bolt (12) for strap (2) and strap (10). Hand tighten the bolts. Ensure that the straps are correctly located onto the diesel exhaust fluid tank.
Tighten bolt (4) and bolt (12) to strap (2). Refer to the OEM for the correct torque procedure and the correct value.
Install diesel emission fluid line (7) and diesel emission fluid line (6) to manifold DEF heater (3). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.
Remove the caps from hose assembly (8) and hose assembly (9) to manifold DEF heater (3). Connect the hose assemblies to the manifold DEF heater. Ensure that the hose assemblies are installed into the correct positions. Tighten the hose clamps. Refer to the OEM for the correct torque value.
Remove the caps from harness assembly (5), harness assembly (11), and harness assembly (14). Connect the OEM harness assemblies to the harness assemblies. Ensure that the harness assemblies are installed into the correct position.
Install new cable straps (13) to the harness assemblies and the diesel emission fluid lines. Ensure that the cable straps are install in the original position. Note: Ensure that the cable straps meet OEM specifications.
Fill the cooling system to the correct level. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Check" and Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct filling procedure.
Turn the battery disconnect switch to the ON position.