856348 Volvo.Penta Cap

Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-5597 Anti-Seize Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g02527478
Ensure that turbocharger (3) is clean and free from damage. Inspect the turbocharger for wear. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If any part of the turbocharger is worn or damaged, the complete turbocharger must be replaced.
Test wastegate actuator (27) for correct operation. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If any part of the wastegate actuator is worn or damaged, the complete turbocharger must be replaced.
Illustration 2 g02526999
Illustration 3 g02614636
Clean the gasket surface of exhaust manifold (23).
If necessary, install studs (22) (not shown) to turbocharger (3). Tighten the studs to a torque of 18 N m (160 lb in).
If necessary, install studs (24) to exhaust manifold (23). Tighten the studs to a torque of 18 N m (160 lb in).
Install a new gasket (20) (not shown) onto exhaust manifold (23).
Position turbocharger (3) onto exhaust manifold (23). Install nuts (21) and nuts (25) finger tight.
Apply sufficient pressure in Position (A) to ensure that turbocharger (3) is at the lowest point on studs (22) (not shown) and studs (24). Do not release the pressure on the turbocharger in Position (A) until nuts (21) and nuts (25) have been tightened securely.
Tighten nuts (21) and nuts (25) to a torque of 22 N m (195 lb in).
Illustration 4 g02527496
Illustration 5 g02526998
Remove plugs from tube assembly (17). Ensure that tube assembly (17) is clean and free from restriction. Replace any damaged components.
Position a new gasket (15) (not shown) and a new gasket (19) (not shown) onto tube assembly (17).
Remove plugs from turbocharger (3) and the cylinder block.
Position tube assembly (17) onto turbocharger (3) and the cylinder block.
Install bolts (16) and bolts (20).
Install bolt (18) to the clip for tube assembly (17).
Tighten bolts (20) to a torque of 22 N m (195 lb in). Tighten bolts (16) to a torque of 9 N m (80 lb in).Tighten bolt (18) to a torque of 18 N m (159 lb in).
Remove the plug from oil inlet port (28). Lubricate the turbocharger bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor several times in order to lubricate the bearings.
Ensure that hose assembly (14) is clean and free from restriction. Replace any damaged components.
Remove cap from connection on turbocharger (10). Loosely connect hose assembly (14) to connection on turbocharger (10).
Position a new sealing washer (12) (not shown) onto banjo bolt (13).
Install banjo bolt (13) to hose assembly (14) and position the remaining new sealing washer (12) (not shown) onto banjo bolt (13).
Tighten banjo bolt (13) to a torque of 22 N m (195 lb in). Note: Ensure that the hose assembly does not come into contact with the turbine housing as the banjo bolt is tightened.
Tighten tube nut for hose assembly (14) on turbocharger (10) to a torque of 30 N m (265 lb in).
Illustration 6 g02526997
Use Tooling (A) to lubricate the allen head bolt for V-band clamp (6). Position V-band clamp (6) onto air duct (7).
Position hose assembly (11) and air duct (7) onto the outlet of turbocharger (10) and turbocharger (3). Tighten the allen head bolt for V-band clamp to a torque of 12 N m (106 lb in).
Tighten hose clamps (11) securely.
Ensure that elbow (1) is free from wear and damage. If necessary, replace the elbow.
Use Tooling (A) to lubricate the allen head bolt for V-band clamp (2). Position V-band clamp (2) onto elbow (1).
Use Tooling (A) to lubricate the allen head bolt for V-band clamp (9). Position V-band clamp (9) onto turbocharger (10).
Position elbow (1) onto turbocharger (3) and turbocharger (10).
Tighten the allen head bolt for V-band clamp (2) and the allen head bolt for V-band clamp (7) finger tight. Ensure that the V-band clamps are seated correctly onto the turbochargers.
Tighten the allen head bolt for V-band clamp (2) and the allen head bolt for V-band clamp (9) to a torque of 12 N m (106 lb in).
Connect hose assembly (5) to the wastegate actuator. Slide hose clamp along hose assembly (5) ensure that hose clamp is correctly positioned.
Connect hose assembly to air outlet (4) to turbocharger (3). Tighten the hose clamps securely.