812498A 1 Mercruiser VALVE KIT, Relief

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more information. If the turbocharger is worn, the complete turbocharger must be replaced.
Illustration 1 g06483198
If necessary, follow Step 2a through Step 2e to install tube assembly (13).
Install a new O-ring seal (35) (not shown) to the adapter. Ensure that the O-ring seal is correctly seated into the recess of the adapter.
Install tube assembly (13) and loosely install bolt (32) to pipe clamp (33), and bolt (32) to pipe clamp (33) on the tube assembly.
Connect tube nut (36) to the adapter hand tight.
Tighten tube nut (36) to a torque of 45 N m (33 lb ft). Use a suitable tool to hold the adapter as the tube nut is tightened.
Tighten bolt (32) and bolt (37) to a torque of 10 N m (89 lb in).
Illustration 2 g06483093
If necessary, follow Step 3a through Step 3g to install tube assembly (21).
If necessary, follow Step 3b through Step 3d to assemble tube assembly (21) and tube assembly (28).
Install new hose clamp (30) to tube assembly (29). Ensure that the new hose clamp is correctly orientated. Install hose (26) to the tube assembly and align temporary marks.
Use a suitable tool to compress and slide the hose clamp onto the hose assembly.Note: Ensure that the hose clamps are correctly positioned onto the hose assembly.
Install new hose clamp (31) to tube assembly (21). Ensure that the new hose clamp is correctly orientated. Install the tube assembly into hose (26) and align temporary marks.
Use a suitable tool to compress and slide the hose clamp onto the hose assembly.Note: Ensure that the hose clamp is correctly positioned onto the hose assembly.
Install a new gasket (27) (not shown) to tube assembly (29). Ensure that the gasket is correctly positioned onto the tube assembly.
Position tube assembly (29) onto the cylinder block. Install bolts (28). Tighten the bolt to a torque of 10 N m (89 lb in).
Illustration 3 g06483085
Illustration 4 g06152320
Ensure that the gasket surfaces of turbocharger (8) and exhaust manifold (21) are clean and free from wear or damage.
Install studs (22) and stud (23) to turbocharger (8). Tighten the studs to a torque of 11 N m (97 lb in).
Install a new gasket (18) (not shown). Ensure that the gasket is correctly orientated.
Install new gasket (19) onto tube assembly (21). Ensure that the gasket is correctly orientated.
Install turbocharger (8) to exhaust manifold (16).
Install nuts (17) and Allen head bolts (20) hand tight.
Tighten nuts (17) to a torque of 21 N m (186 lb in).
Tighten nuts (17) to an additional torque of 28 N m (248 b in).
Tighten Allen head bolts (20) to a torque of 12 N m (106 lb in).
Illustration 5 g06331626
Lubricate the bearings of the turbocharger with clean engine oil through the oil inlet port in position (X). Rotate the shaft of the turbocharger to distribute the lubricant.Note: Ensure that the used O-ring has been removed from the banjo bolt (12)
Install a new O-ring seal (14) (not shown) , and install new O-ring seal (16) (not shown) to tube assembly (13). Install banjo bolt (12) to the tube assembly.
Install banjo bolt (12) to turbocharger (8). Tighten the banjo bolt to a torque of 15 N m (133 lb in).
Illustration 6 g06483071
Install a new gasket (9) (not shown) between turbocharger (8) and exhaust adapter (12). Ensure that the gasket is correctly orientated and is aligned to the bolt holes in the turbocharger.
Install bolts (13) to exhaust adapter (12). Tighten the bolts to a torque of 44 N m (32 lb ft).
Tighten bolts (10) to a torque of 15 N m (133 lb in)
Illustration 7 g06483088
Position heat shield (24) onto bolts (25) and tighten the bolts finger tight.
Tighten the bolts (25) to a torque of 9 N m (80 lb in).
Illustration 8 g06152286
Connect inlet tube assembly (4) to the inlet of the turbocharger.
Install breather hose assembly (1) to inlet tube assembly (4), Ensure the hose clamps (6) are correctly positioned.
Tighten the hose clamps to a torque of 4.5 N m (40 lb in). for inlet tube assembly (4). Ensure that the inlet tube assembly is correctly orientated.
Use a suitable tool to expand hose clamp (2) and slide into position on the breather hose assembly (1) . Ensure that the hose clamp is correctly positioned onto the breather hose.
Connect harness assembly (5) to wastegate actuator (3).
Test the turbocharger actuator for correct operation. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more information. If the actuator is damaged or the actuator does not operate within the specified limits, the actuator must be replaced using the correct service kit.
Run an air systems motor valve verification test. Refer to Troubleshooting, "Air Systems Motor Valve Verification Test" for the correct procedure.