3802103 Volvo.Penta Turbocharger

Start By:a. remove hood
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 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 the skin and eyes to prevent personal injury.
1. Release the pressure in the cooling system by slowly loosening the filler cap on the radiator. Drain the coolant from the radiator. The capacity of the cooling system is 49 liters (12.7 U.S. gal).2. Remove the engine compartment doors. Remove the crankcase guard from under the engine.
View From Under Machine3. Drain the oil from the transmission/torque converter oil cooler by removing plugs (5) from tube assemblies (1).4. Remove eight bolts (3) and the washers to disconnect tube assemblies (1) from the transmission/torque converter oil cooler.5. Remove two bolts (2) that hold battery cable mounting brackets (6) to the transmission/torque converter oil cooler.6. Disconnect two hoses (4), and drain the oil from them. 7. Remove four bolts (8), and remove radiator enclosure panel assembly (7).8. Disconnect upper radiator hose (9). 9. Fasten a lifting sling and a hoist to fan adapter (10) as shown.
Do not damage the radiator cores or hydraulic oil cooler cores when the fan assembly and adapter are placed against them.
10. Remove six bolts (11), and carefully place the fan assembly and fan adapter against the radiator cores and the hydraulic oil cooler cores. 11. Fasten tool (A) to the radiator top tank assembly as shown. Fasten a hoist to radiator guard and radiator (12). 12. Disconnect lower radiator hose (13).13. Disconnect wiring harness (14) and the clamp.14. Remove four bolts (15) and the washers that hold the radiator guard and radiator to the frame of the machine. Remove the radiator guard and radiator as a unit. The weight of the unit is 590 kg (1300 lb). The following steps are for the installation of the radiator guard and radiator. 15. Fasten tool (A) to the radiator top tank assembly. Fasten a hoist to radiator guard and radiator (12). Put the unit in position on the frame of the machine. Install four bolts (15) and the washers that hold it.16. Reconnect wiring harness (14) and the clamp.17. Connect lower radiator hose (13).
Do not damage the radiator cores or hydraulic oil cooler cores when the fan assembly and adapter are installed.
18. Fasten a lifting sling and a hoist to fan adapter (10) as shown. Put the fan adapter with the fan assembly in position on the fan drive, and install six bolts (11) that hold it. 19. Connect upper radiator hose (9).20. Put radiator enclosure panel assembly (7) in position on the radiator guard, and install four bolts (8) that hold it.
View From Under machine21. Reconnect two hoses (4).22. Connect battery cable mounting brackets (6) to the transmission/torque converter oil cooler with two bolts (2).23. Connect two tube assemblies (1) to the transmission/torque converter oil cooler with eight bolts (3). Be sure two drain plugs (5) are tight.24. 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.25. Start the machine, and check for leaks. Reinstall the crankcase guard under the engine. Install the engine compartment doors.End By:a. install hood