21776918 Volvo.Penta Charge air cooler

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     5P-3931     Anti-Seize Compound     -    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
The alignment of the bellows is important. Improper alignment may lead to premature failure of the bellows. Misalignment can be identified by visually inspecting the convolutions for uniformity of compression.Inspect the bellows for damage prior to installation. If there is any damage to the convolutions, discard the bellows. Minor damage to the ends of the bellows may be repaired. However, if there is any difficulty in installation after the repair, discard the bellows.
Illustration 1 g01004383
Illustration 2 g01502594
The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.
Note: Refer to Special Instruction, REHS1728, "Application Guideline for the Bellows" for additional information on handling the bellows.
Install a new seal (17) and backup ring (16) in bellows (18) .
Use a suitable lifting device in order to install turbocharger (14) on the exhaust manifold and in the bellows on the precooler. The weight of the turbocharger is approximately 25 kg (55 lb).Note: If necessary, loosen clamp (13) and rotate the turbocharger housing in order to align the bellows for assembly.Note: Discard the locknuts after use. Use new locknuts for installation.
Apply Tooling (A) to the threads of the studs. Apply Tooling (A) to the mating surface of locknuts (12) . Install locknuts (12) . Tighten locknuts (12) in a numerical sequence to a torque of 54 5 N m (40 4 lb ft). Refer to Illustration 2.
Install clamp assembly (15) . Apply Tooling (A) to the threads of the clamp assembly and tighten to a torque of 12 2 N m (106 18 lb in).
If clamp assembly (13) was loosened, apply Tooling (A) to the threads of the clamp assembly and tighten to torque of 16 1 N m (142 9 lb in).
Illustration 3 g01003348
Connect hose assembly for the oil drain (11) (not shown).
Connect hose assembly for the oil supply (3) .
Connect hose (8) .
The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.
Note: Refer to Special Instruction, REHS1728, "Application Guideline for the Bellows" for additional information on handling the bellows.
Install bellows (6) and duct (1) to the turbochargers.
Install clamp assembly (7) . Apply Tooling (A) to the threads of the clamp assembly and tighten to a torque of 12 4 N m (106 35 lb in).
Install clamp assembly (2) . Apply Tooling (A) to the threads of the clamp assembly and tighten to a torque of 12 4 N m (106 35 lb in).
The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.
Note: Refer to Special Instruction, REHS1728, "Application Guideline for the Bellows" for additional information on handling the bellows.
Install bellows (10) and duct (5) on the turbochargers.
Install clamp assembly (9) . Apply Tooling (A) to the threads of the clamp assembly and tighten to a torque of 12 4 N m (106 35 lb in).
Install clamp assembly (4) . Apply Tooling (A) to the threads of the clamp assembly and tighten to a torque of 12 4 N m (106 35 lb in).