3803904 Volvo.Penta Starter motor, exch

Table 1
Required Tools
Tool Part Number Part Description Qty
A 487-8643 Tool As 1
B 339-9353 Cap Kit 1
265-2256 Lint Free Wipes 1
C 246-8191 Socket 1
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.
Do not open the high pressure fuel system without allowing the fuel system to purge. After the engine has shut down, allow the fuel system to purge for ten minutes. This operating fuel system contains high pressure. Exposure to high pressure fuel can result in personal injury.
Note: Use Tooling (B) to cap tube assemblies, fittings, ports, and any openings on the fuel system to prevent contamination.Note: When replacing the fuel pump, replace the oil screen in the fuel pump adaptor.
Illustration 1 g03871386
Remove clamp assembly (8), hose assembly (1), hose assembly (2), hose assembly (4), and hose assembly (3). Remove clamp assembly (7) and hose assembly (6). Disconnect harness assembly (5).
Illustration 2 g03871410
Remove bolt (11). Disconnect harness assembly (16) from the fuel pump.
Remove tube assembly (9) and hose assembly (10).
Remove bolts (12) and plate assembly (11).
Remove bolts (13) and bracket assembly (14).
Illustration 3 g03871453Note: When the fuel lines are removed, use clean engine oil to lubricate the outside diameter of tube assembly (22) in Area (X). Use Tooling (C) to remove bolts (18) and (21). Contamination and fuel leaks may occur If the procedure is not followed.
Remove bolt (23) and clamp assembly (19). Remove and discard bolts (18) and bolts (21).
Remove tube assembly (22) and the O-ring seals.
Illustration 4 g06301855
Typical Example
Use Tooling (A) and attach a suitable lifting device onto fuel pump (17). The weight of fuel pump (17) is approximately 157 kg (346 lb). Refer to Tool Operating Manual, M0080739 , "HPFP". Remove bolts (20). Lower fuel pump (17) to the ground.Note: The lifting device should not come into contact with the fuel shutoff valve which will result in damage to the component.! Magnetic lift of the high-pressure fuel pump is prohibited.
Illustration 5 g03871734
Remove bolts (24), bolts (26), fuel manifold (25), fuel transfer pump (27).
Illustration 6 g03871901
Remove and discard oil screen (28).Installation Procedure
Install fuel pump (17) in the reverse order of removal.
Install new oil screen (28).
Lubricate the O-ring seals with clean engine oil. Lubricate the ends of tube assembly (22) with clean engine oil. Install the O-ring seals on tube assembly (22). Install tube assembly (22). Install new bolts (21) hand tight. Install new bolts (18) hand tight. Position clamp assembly (19). Install bolt (23). Use Tooling (C) and evenly tighten bolts (21) to a torque of 20 N m (177 lb in). Use Tooling (C) and evenly tighten bolts (18) to a torque of 20 N m (177 lb in).
Evenly tighten bolts (21) to a torque of 40 N m (30 lb ft). Evenly tighten bolts (18) to a torque of 40 N m (30 lb ft). Tighten bolt (23).Note: Do not rotate bolts (21) and (18) more than 45 degrees at a time.