7746450_104 Volvo.Penta thermostat and water pump with installation comps

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     8T-5255     Hydraulic Jack     1    
B     1U-9200     Lever Puller Hoist     1    
C     180-3033     Repair Stand Set     2    
D     185-3630     Strap Wrench As     1    
ZZ     9U-7067     Tapered Cap/Plug     1    
9U-7069 Tapered Cap/Plug     2    
9U-7071 Tapered Cap/Plug     1    
9U-7073 Tapered Cap/Plug     4    
9U-7075 Tapered Cap/Plug     2    
9U-7079 Tapered Cap/Plug     1    
9U-7081 Tapered Cap/Plug     1    Start By:
Remove the fan guard. Refer to Disassembly and Assembly, "Fan Guard - Remove and Install".
Remove the radiator. Refer to Disassembly and Assembly, "Radiator - Remove and Install".
Remove the muffler. Refer to Disassembly and Assembly, "Muffler - Remove and Install".
Remove the air cleaner. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".
Remove the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install".
Remove the floorplate. Refer to Disassembly and Assembly, "Floorplate - Remove and Install".
Remove the fuel filter and the water separator. Refer to Disassembly and Assembly, "Fuel Filter and Water Separator - Remove and Install".Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.
Personal injury can result from contact with refrigerant.Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area.Personal injury or death can result from inhaling refrigerant through a lit cigarette.Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death.Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.
Recover the air conditioner refrigerant from the air conditioner system. The correct charge is 1.4 kg (3.1 lb). Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the correct tools.
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, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Drain the transmission oil into a suitable container. Refer to Operation and Maintenance Manual, "Transmission Oil - Change".
Illustration 1 g01039942
Disconnect harness assemblies (1). Disconnect harness assemblies (2). Position harness assembly (3) out of the way. Remove bolts (4) and position manifold (5) out of the way.
Illustration 2 g01040203
Disconnect hose assemblies (6). Disconnect hoses (7). Disconnect fuel hoses (8). Disconnect governor linkage (9) .
Illustration 3 g01040206
Disconnect harness assemblies (10). Position harness assemblies (10) out of the way.
Illustration 4 g01040208
Remove bolts (11) and bolt (12) .
Illustration 5 g01040210
Disconnect ground cable (13) .