7746600_093 Volvo.Penta Charge air cooler

1. Fasten a lifting sling and a hoist to muffler (1) as shown. Put slight lifting tension on the muffler. 2. Loosen clamp (2) that holds exhaust elbow (4) to muffler (1).3. Remove three bolts (3) and exhaust elbow (4) and its coupling. 4. Loosen three clamps (7), and disconnect two air hoses (5).5. Remove the two bolts, and disconnect oil supply tube (9) from the turbocharger.6. Remove the two bolts, and disconnect oil drain tube (10) from the turbocharger.7. Remove four locknuts (6). Remove turbocharger (8) and the gasket from the exhaust manifold. The following steps are for the installation of the turbocharger.
Before four locknuts (6) which hold the turbocharger to the exhaust manifold are tightened, all oil tubes, air pipes and exhaust pipes should be aligned and tightened without binding.
8. Check the condition of the gasket used between the turbocharger and the exhaust manifold. If the gasket is worn or damaged, use a new part for replacement. Put the gasket and turbocharger (8) in position on the exhaust manifold. Put 5P3931 Anti-Seize Compound on the threads of the studs that hold the turbocharger to the exhaust manifold. Install the four locknuts, but do not tighten them at this time.9. Check the condition of the gaskets used on oil supply tube (9) and oil drain tube (10). If the gaskets are worn or damaged, use new parts for replacement. Connect the oil supply tube and the oil drain tube to the turbocharger.10. Connect two air hoses (5) to the turbocharger, and tighten three clamps (7).11. Install the coupling and exhaust elbow (4). Install three bolts (3).12. Tighten clamp (2) that holds exhaust elbow (4) to muffler (1).13. Tighten four locknuts (6) that hold the turbocharger to the exhaust manifold to a torque of 54 5 N m (40 4 lb ft).Disassemble & Assemble Turbocharger
For other topics of Disassembly & Assembly for the engine not covered in this module, see the module, 3114 & 3116 Diesel Engines, Form No. SENR3611.Start By:a. remove turbocharger 1. Remove bolts (1) and (2). Remove the compressor and turbine housing. 2. Remove nut (3) and compressor wheel (4). Slide turbine wheel (5) and the shaft out. Remove the piston ring from the shaft. 3. Remove adapter plate snap ring (6).4. Using two screwdrivers, remove adapter plate (7). 5. Remove the flinger sleeve, bearing (8), spacers (9) and seals (10). 6. Remove snap ring (11), bushing (12) and the other snap ring. 7. Remove snap ring (13), bushing (14) and the other snap ring. The following steps are for the assembly of the turbocharger.8. Be sure all parts of the turbocharger are thoroughly clean and free of dirt and debris.9. Install bushing (12) and snap ring (11). Repeat this procedure for bushing (14) and snap ring (13). Install the piston ring on the turbine wheel end of the shaft. 10. With the seals and shield (15) in place, install shaft and turbine wheel assembly (5). Bearing (8) locates on the pin in the bearing housing assembly.11. Install the spacers, bearing, plate, seals and adapter plate. Install the snap ring (not shown).
Do not allow any of the 9S3263 Thread Lock to get on the shaft. Damage to the turbocharger may occur.
12. Install compressor wheel (4) on the shaft. Put one drop of 9S3263 Thread Lock on the threads, and install nut (3). Tighten nut (3) to a torque of 10.2 .6 N m (90 5 lb. in.)13. Position the turbine and compressor housings. Put 5P3931 Anti-Seize Compound on the bolts, and install them. Tighten bolts (1) for the compressor cover to a torque of 7.3 .6 N m (65 5 lb. ft.). Tighten bolts (2) for the turbine housing to a torque of 15.8 .6 N m (140 5 lb. ft.).End By:a. install turbocharger