804221 Volvo.Penta Adjusting washer

Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.
Do not strike any part of the assembly of the Diesel Particulate Filter (DPF). Do not allow any object to contact the internal element of the DPF. If the internal element of the DPF becomes damaged, the assembly must be replaced.Do not use power tools in order to disassemble or assemble any part of the Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), or the outlet section.
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Illustration 1 g02330913
Illustration 2 g02332737
In certain applications, it will be necessary to install the assembly of the Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), and the outlet cannister as an assembly.
Follow Step 3.a through Step 3.l in order to install the DOC, DPF, and outlet cannister as an assembly (1).
Position a new ball clamp (5) onto the inlet of DPF assembly (1).
Attach a suitable lifting device to DPF assembly (1). The weight of the DPF assembly is approximately 66 kg (145 lb).
Use the suitable lifting device to position DPF assembly (1) onto the bracket for clean emission module (6).
Align DPF assembly (1) with flexible bellows (7).
Install ball clamp (5) onto flexible bellows (7). Tighten the ball clamp finger tight.
Position clamp (2) and clamp (3) onto DPF assembly (1). Install the nuts to clamp (2) and clamp (3). Note: Ensure that the DPF assembly is correctly positioned on the bracket for clean emission module.
Tighten bolt for ball clamp (6) to a torque of 18 N m (159 lb in).
Tighten nuts for clamp (2) and clamp (4) to a torque of 18 N m (159 lb in).
Install the tube assemblies for the pressure sensor to the DPF assembly. Refer to Disassembly and Assembly, "Pressure Sensor (DPF) - Remove and Install" for the correct procedure.
Install the soot antennas to the DPF assembly. Refer to Disassembly and Assembly, "Soot Antenna - Remove and Install" for the correct procedure.
Install the temperature sensors to the DPF assembly. Refer to Disassembly and Assembly, "Temperature Sensor (DPF) - Remove and Install" for the correct procedure.
If necessary, install the Original Equipment Manufacturers (OEM) exhaust system to outlet cannister (4) of the clean emission module. Alternative Installation Procedure for the Diesel Particulate Filter
Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.
Do not strike any part of the assembly of the Diesel Particulate Filter (DPF). Do not allow any object to contact the internal element of the DPF. If the internal element of the DPF becomes damaged, the assembly must be replaced.Do not use power tools in order to disassemble or assemble any part of the Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), or the outlet section.
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Illustration 3 g02331135
Illustration 4 g02334016
In certain applications, it will be necessary to install outlet section (4) or the Diesel Oxidation Catalyst (DOC) (8) after the Diesel Particulate Filter (DPF) has been installed. If necessary, install the DPF. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Assemble" for the correct procedure.
If necessary, install the DOC after the DPF has been installed. Refer to Disassembly and Assembly, "Catalyst (Diesel Oxidation Catalyst) - Remove and Install" for the correct procedure.
Position a new Torca clamp (7) in Position (B) onto the DPF. Ensure that the Torca clamp is correctly orientated.
Attach a suitable lifting device to outlet section (4). The weight of the outlet section is approximately 15 kg (33 lb).
Use the suitable lifting device to position outlet section (4) to the DPF.
Rotate outlet section (4) in a clockwise direction in order to engage the pins and slots (10).
If necessary, install the Original Equipment Manufacturers (OEM) exhaust tube assembly to outlet section (4). Ensure that the outlet section is correctly aligned.
Position Torca clamp (7) between DPF and the outlet section. Align the Torca clamp with the temporary marks in Position (A). Tighten the nuts on the Torca clamp hand tight.
Tighten the nut on clamp (3) hand tight.
Tighten nuts for Torca clamp (7) to a torque of 42 N m (31 lb ft).
Tighten nut for clamp (3) to a torque of 18 N m (159 lb in).
Install the soot antenna to outlet section (4). Refer to Disassembly and Assembly, "Soot Antenna - Remove and Install" for the correct procedure.
Install the tube assembly for the pressure sensor to outlet section (4). Refer to Disassembly and Assembly, "Pressure Sensor (DPF) - Remove and Install" for the correct procedure.
If a replacement DPF has been installed, or an ash service has been carried out, use the electronic service tool in order to reset the engine ash model. Refer to System Operation, Testing and Adjusting, "Diesel Particulate Filter - Clean"