7746600_092 Volvo.Penta Charge air cooler

1. Loosen the hose clamp that holds hose (2) to elbow (1).2. Remove the bolts that hold elbow (1) in place, and remove the elbow. 3. Disconnect two wires (6) from the switch.4. Remove the bolts that hold elbow (5), and pull the elbow out of the aftercooler.5. Remove the bolts that hold shields (3) and (4), and remove the shields from the engine. 6. Remove elbow (7) from the front of the aftercooler.
Typical Example7. Remove sleeve (9) and adapter (8) from the rear of the aftercooler.
Typical Example8. Remove sleeve (11) and adapter (10) from the front of the aftercooler.
Typical Example9. Fasten a hoist and tooling (A) to housing (12). Remove the bolts that hold the housing to the engine, and remove the housing. The weight of the housing is 68 kg (150 lb).
Typical Example10. Remove the bolts that hold core assembly (13) to the engine. Fasten a hoist to the core assembly, and remove it from the engine. The weight of the core assembly is 49 kg (108 lb).
Typical Example11. Remove O-ring seals (14) from each end of core assembly (13).12. Remove ring (15) and connector (16) from the core assembly.13. Remove four O-ring seals (17) from the connector.Install Aftercooler
Typical Example1. Put four O-ring seals (4) in position on connector assembly (3). Put glycerin on the O-ring seals.*If disassembled, assemble connector assembly (3).
Illustration of connector assembly (3). 5. Plug. 6. Connector. 7. Valve Assembly.2. Put the connector in position in core assembly (1), and install ring (2).
Typical Example
Typical Example3. Put O-ring seals (8) in position on each end of core assembly (1).4. Align the connector in the bottom of the core assembly with adapter (9). Install core assembly (1). Install the bolts that hold the core assembly in place. 5. Fasten a hoist and tooling (A) to housing (10). Put the gasket and housing (10) in position, and install the spacers and bolts to hold it in place. Tighten the bolts to a torque of 55 7 N m (41 5 lb ft). 6. Make sure O-ring seal (12) is in position on adapter (11).7. Put glycerin on the bores of the adapter and the housing. Install adapter (11) and the sleeve in the front of the aftercooler. 8. Make sure O-ring seal (14) is in position on adapter (13).9. Put glycerin on the bores of the adapter and the housing. Install adapter (13) and the sleeve in the rear of the aftercooler. 10. Install elbow (15) on the front of the aftercooler. 11. Install shields (16) and (17) over the exhaust manifolds.12. Make sure the gasket is in position on the cylinder block. Put adapter (18) in position in the end of the aftercooler and on the cylinder block. Install the bolts that hold it.13. Connect two wires (19) to the switch. 14. Install the gasket on adapter (18).15. Put elbow (21) in position in hose (20) and on adapter (18). Install the bolts that hold elbow (21) to the adapter.16. Tighten the hose clamp that holds hose (20) to the elbow.End By:a. install turbocharger