22845783 Volvo.Penta Box

1. Remove two bolts (1) from each end of oil drain tube (3). Remove oil drain tube (3).2. Remove tube (4).3. Remove four bolts (2). 4. Remove two bolts (7) from the oil supply line. Remove the oil supply line and the gasket from the turbocharger.5. Remove four nuts (8). 7. Using a hoist and a strap, remove the turbocharger from the engine. The weight of the turbocharger is 38 kg (84 lb). The following steps are for the installation of the turbocharger. Check all O-ring seals for wear or damage and replace as required. After installing the O-ring seals, coat them with clean engine oil.8. Using a strap and a hoist, position the turbocharger on the engine.9. Install four bolts (2) to mount the adapter to the turbocharger.10. Install the oil drain tube with four bolts (4).11. Connect tube (4) to the engine and the turbocharger.12. Make sure the gasket is in place and install the oil supply line with the two bolts.13. Put 5P3931 Anti-Seize Compound on the threads of the exhaust manifold studs and nuts (8). Install four nuts (8). Tighten to a torque of 54 5 N m (40 4 lb ft).14. Install inlet tube (5) and tube (7).Disassemble Turbocharger
Start By:a. remove turbocharger 1. Install the turbocharger on tool group (A). Mark the three housings of the turbocharger for correct alignment at assembly.2. Loosen clamp (2), and remove compressor housing (1) and the clamp. 3. Loosen clamp (5), and remove cartridge assembly (3) from turbine housing (4).
To prevent a bent shaft, do not put a side force on the turbine shaft when the compressor wheel nut is loosened.
4. Put the end of the turbine shaft in tool (B). Use a universal joint and socket of the correct size to remove the nut that holds compressor wheel (6). 5. Using a press, push the turbine shaft out of compressor wheel (6) and the cartridge housing. Remove compressor wheel (6). 6. Remove seal ring (8) and shroud (9) from turbine shaft (7). 7. Bend the tabs of the locks from bolts (10) and remove the bolts.8. Note the position of the oil holes in the backplate assembly and cartridge housing for correct alignment at assembly. Remove backplate assembly (11). 9. Remove spacer (12) from backplate assembly (11). 10. Remove seal rings (13) from spacer (12). 11. Remove thrust collar (14) and seal ring (15). 12. Remove thrust bearing (16). If the bearings are to be used again, put identification marks on them as to their location for correct assembly.13. Remove bearing (17) and the washer below the bearing from the cartridge housing. 14. Using tool (C), remove snap rings (18) and (19). 15. Remove bearing (20) and washer (21). 16. If necessary, use tool (C) and compress the end snap ring pushing it out of the bearing bore toward the compressor end of the cartridge housing to remove it.Assemble Turbocharger
1. Make sure all of the oil passages in the turbocharger cartridge housing, the backplate assembly and the bearing are clean and free of dirt and foreign material.2. Put clean engine oil on all parts of the cartridge at assembly. Make sure the round edge on the outside diameter of the snap rings are toward the bearings when the snap rings are installed. 3. Using tool (C), install snap ring (22) in the turbine end of the cartridge housing.4. Install washer (21) and bearing (20). Using tool (C), install snap ring (19). 5. Using tool (C), install snap ring (18). 6. Install washer (23) and bearing (17) in the cartridge housing until washer (23) makes contact with snap ring (18). 7. Install thrust bearing (16) over the dowels in the cartridge housing. Make sure the grooves in bearing (16) are toward the outside as shown. 8. Install seal ring (15) in the groove of the cartridge housing. 9. Install thrust collar (14) on the thrust bearing with the counterbore for the spacer up. 10. Install seal rings (13) on spacer (12) so the gaps in the rings are 180° apart. 11. Install spacer (12) in backplate assembly (11). 12. Align oil passage (24) in the cartridge housing with oil passage (25) in the backplate assembly. Install backplate assembly (11) on cartridge housing. Make sure the spacer fits correctly in the counterbore of the thrust collar. 13. Install the locks and bolts to hold backplate assembly (11) to the cartridge housing. Tighten the bolts to a torque of 10 1 N m (89 9 lb in). Bend the tabs of the locks on the bolts. 14. Install turbine shaft (7) in tooling (B). Put 6V2055 High Vacuum Grease in the groove for seal ring (8). Make sure the grease fills the groove a minimum of one half of the groove depth for the complete circumference of the groove. This helps make a carbon dam under the seal ring. Install seal ring (8) and shroud (9). 15. Install the cartridge housing on the turbine shaft while spacer (12) is held n position. Make sure the seal ring on the turbine is fitted correctly in the cartridge housing. 16. Install compressor wheel (6).
Do not put a side force on the turbine shaft when the nut is tightened, or a bent shaft will be the result.
17. Put a small amount of oil on the turbine shaft threads and the compressor wheel face that will be under the nut. Install the nut and tighten to a torque of 17 N m (150 lb in) to push compressor wheel (6) on the shaft. Loosen the nut, and tighten it again to 3.5 N m (31 lb in). Tighten the nut 120° of a turn more.18. Remove the nut from the turbine shaft, and put 6V1541 Quick Cure Primer on the threads of the turbine shaft and nut.19. Put 9S3265 Retaining Compound on the threads of the shaft and nut. Install the nut and tighten it to a torque of 3.5 N m (31 lb in). Tighten the nut an