3801389 Volvo.Penta Cylinder head, exch

Sulfuric Acid Burn Hazard may cause serious personal injury or death.The exhaust gas cooler may contain a small amount of sulfuric acid. The use of fuel with sulfur levels greater than 15 ppm may increase the amount of sulfuric acid formed. The sulfuric acid may spill from the cooler during service of the engine. The sulfuric acid will burn the eyes, skin and clothing on contact. Always wear the appropriate personal protective equipment (PPE) that is noted on a material safety data sheet (MSDS) for sulfuric acid. Always follow the directions for first aid that are noted on a material safety data sheet (MSDS) for sulfuric acid.
Illustration 1 g02477077
Drain the coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining procedure.
Remove bolts (2) and bolts (10) from pipe (1).
Remove pipe (1) from exhaust cooler (NRS) (12) and the cylinder head.
Remove gaskets (3) (not shown) and gasket (11) (not shown) from pipe (1).
Prior to and during removal of bolts (4) and bolts (16), apply releasing fluid to the bolts. Remove bolts (4) and bolts (16) from tube assembly (6).
Remove tube assembly (6) from exhaust cooler (NRS) (12) and the exhaust manifold.
Remove gaskets (5) (not shown) and gasket (15) (not shown) from tube assembly (6).
Remove bolts (8) and bolt (14) from pipe (7).
Remove pipe (7) from exhaust cooler (NRS) (12) and the cylinder head.
Remove gasket (9) (not shown) and O-ring seal (13) (not shown) from pipe (7).
Illustration 2 g02477065
Cut cable straps (21) for harness assembly (17). Ensure that all the cable straps are removed from all the harness assemblies.
Slide locking tab (18) into the unlocked position. Disconnect harness assembly (17) from harness assembly (19).
Remove bolts (20) from pipe (23).
Remove bolt (24) from the clamp on pipe (23).
Remove bolts (25) from pipe (23).
Remove pipe (23). Remove gasket (26) (not shown) and gasket (22) (not shown) from pipe (23).
Illustration 3 g02477067
Remove bolt (27) and bolts (28) from exhaust cooler (NRS) (12).Note: The exhaust cooler (NRS) should be supported as the bolts are removed.
Remove exhaust cooler (NRS) (12) from the cylinder block.Installation Procedure
Ensure that the harness assembly is correctly routed and that the cable straps are not over-tightened. Over-tightening of the cable straps will damage the harness assembly.
Ensure that the exhaust cooler (NRS) is clean and free from restriction. Ensure that the exhaust cooler (NRS) is free from wear and damage. If necessary, replace any components that are worn or damaged.Note: Do not disassemble or clean the exhaust cooler (NRS).
Ensure that all the tube assemblies are free from restriction and damage.
Illustration 4 g02477067
Position exhaust cooler (NRS) (12) onto the cylinder block. Install bolt (27) and bolts (28) to exhaust cooler (NRS) (12). Hand-tighten bolt (27) and bolts (28).Note: The exhaust cooler (NRS) should be supported as the bolts are installed.
Tighten bolt (27) and bolts (28) to a torque of 22 N m (195 lb in).
Illustration 5 g02477065
Position a new gasket (22) (not shown) and a new gasket (26) (not shown) onto pipe (23).
Position pipe (23) onto the exhaust cooler (NRS) and the inlet air control. Install bolts (20) and bolts (25) to pipe (23).
Install bolt (24) on the clamp for pipe (23).
Tighten bolts (20) to a torque of 9 N m (80 lb in).Tighten bolts (25) to a torque of 18 N m (159 lb in).Tighten bolt (24) to a torque of 22 N m (195 lb in).
Connect harness assembly (17) to harness assembly (19). Slide locking tab (18) into the locked position.
Install new cable straps (21) to harness assembly (17).Note: Ensure that the cable straps meet the Original Equipment Manufacturers (OEM) specification.
Illustration 6 g02477077
Position a new gasket (3) (not shown) and a new gasket (11) (not shown) onto pipe (1).
Install pipe (1) to exhaust cooler (NRS) (12) and the cylinder head.
Install bolts (2) and bolts (10) to pipe (1).
Tighten bolts (10) to a torque of 18 N m (159 lb in).Tighten bolt (2) to a torque of 22 N m (195 lb in).
Position a new gasket (9) (not shown) and install a new O-ring seal (13) (not shown) onto pipe (7).Note: Do not lubricate the O-ring seal.
Position pipe (7) onto exhaust cooler (NRS) (12) and the cylinder head. Install bolts (8) and bolt (14) to pipe (7). Ensure that the pipe is correctly positioned into the exhaust cooler (NRS).
Tighten bolt (14) to a torque of 18 N m (159 lb in).Tighten bolts (8) to a torque of 22 N m (195 lb in).
Position a new gasket (5) (not shown) and a new gasket (15) (not shown) onto tube assembly (6).
Position tube assembly (6) onto exhaust cooler (NRS) (12) and the exhaust manifold.
Install new bolts (4) and new bolts (16) to tube assembly (6).
Tighten bolts (4) and bolts (16) to a torque of 22 N m (195 lb in).
Fill the coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct filling procedure.End By:
Install the turbocharger (first stage).
Install the turbocharger (second stage).