956081 Volvo.Penta Cross recessed screw

1. Remove turbocharger oil supply line (4) and oil return line (6).2. Remove bolts (5) that hold pipe (1), flange (2) and bracket (3) to the aftercooler cover. Remove the bolt and washer and remove pipe (1) from the turbocharger. 3. Remove bolts (9) and nuts that hold turbocharger (7) and shield (8) to the exhaust manifold. Remove turbocharger (7) and gasket from the exhaust manifold.Install Turbocharger
1. Inspect all O-ring seals and gaskets for damage and make replacements if needed. Put clean oil on the O-ring seals. 2. Put gasket (2) and turbocharger (1) in position on the exhaust manifold. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold the turbocharger to the exhaust manifold. Put shield (3) in place and install the bolts and nuts that hold the shield and turbocharger in place. Tighten the bolts to a torque of 54 5 N m (40 4 lb.ft.). 3. Install pipe (8) in the turbocharger. Install the washer and bolt that hold the pipe in the turbocharger.4. Put gasket (4) and bracket (6) in place and install the bolts that hold the pipe and flange to the aftercooler cover. Tighten the bolt that holds the pipe in the turbocharger.5. Put the gaskets in place and install turbocharger oil return line (7) and oil supply line (5). end by:a) install mufflerb) install air cleaner assemblyDisassemble Turbocharger
start by:a) remove turbocharger1. Put the turbocharger in position on tool (A). 2. Put a mark on compressor cover (1), the cartridge and the turbine housing for correct alignment and installation at assembly.3. Loosen V-clamp (2). Remove compressor cover (1) and V-clamp (2) from the cartridge. 4. Loosen V-clamp (3). Remove the cartridge from turbine housing (4). 5. Put the cartridge in position in tool (B).
When the nut is loosened, do not put a side force on the shaft.
6. Remove the nut and compressor wheel (5) from the shaft. 7. Remove the cartridge from tool (B) and remove turbine wheel (7) and the shaft from the cartridge.8. Remove seal ring (6) from the turbine wheel. 9. Remove the snap ring and insert (8) from the cartridge. 10. Push sleeve (9) out of the insert. Remove the two seal rings from the sleeve. Remove the O-ring seal from the insert. 11. Remove deflector (10), ring (15), sleeve (11), bearing (12), ring (16), snap ring (13), bearing (17) and snap ring (14) from the cartridge. Remove snap rings (13) and (14) with tool (C). Check the oil hole in bearing (12). If the oil hole is not open this will cause a bearing failure. 12. Turn the housing around and remove snap ring (18) and shroud (22) from the cartridge.13. Remove snap ring (19), sleeve (20), bearing (21) and snap ring (23) from the cartridge. Remove the two snap rings with tool (C).Assemble Turbocharger
1. Clean and inspect all parts. Make a replacement of the parts that are worn or damaged. See SPECIAL INSTRUCTION FORM NO. SMHS6854 for TURBOCHARGER RECONDITIONING. Also see GUIDELINE FOR REUSABLE PARTS FORM NO. SEBF8018.2. Make sure all oil passages are open and clean. Put clean engine oil on all parts before assembly. 3. Install snap ring (4), bearing (3), sleeve (2) and snap ring (1). Use tool (A) to install the two snap rings with the round side of the rings toward the bearing. 4. Install shroud (5) on the cartridge. Turn the shroud to make sure it is down on the cartridge even. The shroud will not turn after assembly because of the high part (web)(6) on the shroud.5. Install the snap ring that holds the shoud in place.6. Install the bearing and two snap rings in the compressor end of the cartridge. Use tool (A) to install the two snap rings with the round side of the rings toward the bearing. Put 6V2055 High Vacuum Grease in the groove for seal ring (7) at assembly to one half or more of the depth of the groove all the way around the shaft. 7. Install seal ring (7) on the shaft. Install turbine wheel (8) and shaft in the cartridge.8. Put cartridge in position in tool (B). 9. Install ring (13), bearing (11), sleeve (12), ring (10) and deflector (9) in the cartridge.
The oil hole in bearing (11) must be open and clean.
10. Install the seal rings on sleeve (15). Install sleeve in insert (14). 11. Install the O-ring seal on the insert and install the insert in the cartridge and install snap ring (17).12. Install compressor wheel (16) on the shaft.13. Put 6V1541 Quick Cure Primer on the nut and the shaft threads to clean them. Put a small amount of 3S3265 Retaining Compound on the nut and shaft threads.
Do not let the retaining compound get into the compressor wheel bore on the shaft, it will make removal of the compressor wheel difficult during future turbocharger disassembly.
14. Put a small amount of lubricant, such as Lubricate, on the area of the nut that makes contact with the compressor. Do not put lubricant on threads.
Do not put a side force on the shaft when the nut is tightened.
15. Install nut (18). Use a torque wrench and flexible socket and tighten the nut to a torque of 60 3 N m (44 2 lb.ft.). 16. Put the cartridge in a vise as shown. Check the shaft end play with tool (D). The end play must be 0.114 0.038 mm (.0045 .0015 in.) (new). The maximum permissible end play with used parts is 0.20 mm (.008 in.). If the shaft end play is not correct, the inside parts of the cartridge housing must be checked for too much wear. See SPECIFICATIONS. 17. Put V-clamp (21) and the cartridge in the correct positions on the turbine housing. Put 5P3931 Anti-Seize Compound on the threads of the V-clamp. Tighten the V-clamp to a torque of 14 N m (120 lb.in.). Use a soft hammer to tap the V-clamp with light pressure to make sure it is