243469 Volvo.Penta Adjusting washer

Problem
789 Trucks equipped with separate air intakes for each side of the engine may have an imbalance in the air intake supply which can effect engine performance.
Affected Product
Model & Identification Number
789 (9ZC1-638)
Parts Needed
2 - 3B6487 Coupling2*- 8B0797 Lug2 - 2D2751 Grommet1 - 3E6691 Film2*- 6I0981 Tube Assembly2 - 6I0982 Tube Assembly2 - 6I1626 Indicator2 - 5M6214 Plug2 - 1P4278 Clamp2 - 4P5212 Hose730 - 5P0756 Tube Stock (400 cm RH side, 330 cm LH side)2 - 5P4423 Elbow4 - 5P4869 Clamp2 - 9S4182 Plug4 - 8T4205 Washer4 - 4V6981 Screw2 - 6V5048 Seal-o-Ring4 - 6V8185 Nut1 - 1W6903 Hose2 - 7W0629 Adapter Assembly1 - 8X9562 Plate6 - 9X6772 Strap*New 6I0981 Tube Assembly can be installed or the existing 7C2986 Tubes can be reworked. Weld 8B0797 Lug on top of the tube in the middle straight section. Drill a hole (.063"- .125") in diameter through the lug into the tube. Remove any burrs on the inside of the tube.Action Required
See the attached Rework Procedure.
Service Claim Allowances
This is a 6-hour job.
If there has been a previous repair, part hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
Install a new balance tube between the air intake supply lines and relocate the air cleaner indicator inside the cab for easier viewing by the operator.
*New 6I0981 Tube Assembly can be installed or the existing 7C2986 Tubes can be reworked. Weld 8B0797 Lug on top of the tube in the middle straight section. Drill a hole (.063"-.125") in diameter through the lug into the tube. Remove any burrs on the inside of the tube.Refer to the previous chart and Illustrations 1 through 5. Remove the items indicated in Illustration 1. Install the new items shown in the steps that follow to complete the installation of the air system balance line, the cab mounted air filter restriction indicator, and the 25" air filter restriction indicator.
1. Remove the items shown in Illustration 1. Refer to Illustration 2 and install the new Hoses (7) on Tubes (11) using the four existing 5P4896 Clamps.2. Install two Tube Assemblies (5) using the existing 5P4869, 5P0600, and 6V4372 Clamps.3. Attach new Hose (6) using four new Clamps (8).4. Install two new Plugs (9) and two new Seals (10) as shown in the new Tube Assemblies (5).5. Install two new Adapters (12) in the " pipe thread boss on the top side of the new Tube Assembly (11) using 5P3413 Pipe thread sealant.6. Connect the new Elbows (13) to the new Adapters (12) installed in Step 5. Use 5P3413 Thread Sealant on the threads.7. Attach Tubing (14) to Elbows (13) installed in Step 6. Route the tubing across the bottom side of the ROPS tube toward the right hand front corner of the cab. Clamp the tube as necessary using 9X6772 Straps.8. Remove the access cover from the front of the cab.9. Drill two 25 mm diameter holes through the right hand front corner of the cab. Locate the hole using the dimensions shown in Illustration 3.10. Install two new Grommets (15) in the 25 mm diameter holes drilled in Step 9.11. Route Tubing (14) from the bottom side of the ROPS tube up to the cab and through the grommet. Clamp the tubing as necessary using 9X6772 Straps.12. If there is a retarder instruction film below the payload monitor display on the front dash, move it to the right hand door. If the film is not movable, a new film from parts stock should be installed on the inside of the right hand door.13. Drill/saw one large slot (70 mm × 150 mm) and four 10.5 mm diameter holes through the front dash panel below the payload monitor display. Locate the holes using the dimensions shown in Illustration 4.14. Route Tubing (14) through the large slot formed in Step 13.15. Attach Film (22) to Plate (17).16. Slide new Gauge Indicators (16) through new Plate (17) and attach the indicators to the plate using the bezel and screws provided with the indicators. The locating notch in Plate (17) orientates Indicator (16).
17. Attach Tubing (14) to Indicators (16) using new Hose Clamps (18). (Cut the tubing to the length required.)18. Slide Indicators (16) into the large slot in the dash panel and attach Plate (17) to the panel with four Screws (19), Washers (20) and Nuts (21).19. Remove the components for the 30" Air Filter Restriction Indicator as follows:A) Remove Coupling (23), Hose (24), Nipple (25), and Indicator (26). See Illustration 5.B) Install Coupling (27) and Plug (28) at the location where Coupling (23) was removed. Use 5P3413 Pipe thread sealant on the threads.
Illustration 1 - Items to be removed
Illustration 2 - Items to be installed
Illustration 3
Illustration 4
Illustration 5