3802102 Volvo.Penta Turbocharger

At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent pesonal injury.
1. Release the pressure in the cooling system. Drain the coolant from the radiator. The capacity of the cooling system is 49 liters (12.7 U.S. gal).2. Remove the crankcase guard from under the engine.3. Release the air pressure in the air tank by pulling on the cable which is fastened to the drain valve on the air tank.
View From Under Machine4. Remove two plugs (1) to drain the oil from the transmission/torque converter oil cooler. 5. Loosen two clamps (2), and disconnect two coolant hoses (3) from the right side of the transmission/torque converter oil cooler. 6. Loosen clamp (4), and disconnect coolant hose (5) from the left side of the transmission/torque converter oil cooler.
View From Under Machine7. Remove eight bolts (7) and the washers that hold tube assemblies (6) to the transmission/torque converter oil cooler.8. Remove two bolts (8), and move the clamps which hold battery cables (9) in position.
View From Under Machine9. Fasten a lifting sling and a hoist to the transmission/torque converter oil cooler as shown.10. Disconnect two air hoses (12) to provide clearance for removal of the oil cooler.11. Remove six bolts (11) from both oil cooler bonnets (10). Lower transmission/torque converter oil cooler (13) out the bottom of the machine. The weight of the oil cooler is 48 kg (106 lb).12. Using the appropriate size diameter rod, clean the tube bundles in the cooler core. The following steps are for the installation of the transmission/torque converter oil cooler.13. Check the condition of the gaskets used between the cooler bonnets and the cooler core. If the gaskets are worn or damaged, use new parts for replacement.14. Fasten a lifting sling and a hoist to transmission/torque converter oil cooler (13). Raise the oil cooler into position from under the machine. Be sure the gasket on each oil cooler bonnet is in position. Install six bolts (11) in each bonnet.15. Reconnect two air hoses (12).16. Put battery cables (9) in position in front of the transmission/torque converter oil cooler. Install two bolts (8) that hold the clamps for the battery cables.17. Check the condition of the o-ring seals used in the ends of tube assemblies (6). If the seals are worn or damaged, use new parts for replacement. Reconnect two tube assemblies (6) to the transmission/torque converter oil cooler.18. Reconnect coolant hose (5) to the left side of the transmission/torque converter oil cooler.19. Reconnect two coolant hoses (3) to the right side of the transmission/torque converter oil cooler.20. Be sure two plugs (1) are tight prior to refilling the transmission/torque converter with oil.21. Fill the transmission/torque converter with oil and the cooling system with coolant to the correct levels. See the Operation & maintenance Manual for the correct filling procedures.22. Start the machine, and check for leaks. Reinstall the crankcase guard under the engine.