7743120_078 Volvo.Penta ELECTRICAL BOX AND INSTALLATION COMPS

Table 1
Specifications for 356-7409 Air Control Gp    
Callout     Part Number     Part Name     Specification Description    
14     6I-0260     Bolt     Torque to...................
22 N m (195 lb in)    
17     6I-0260     Bolt     Torque to...................
22 N m (195 lb in)    
21     6I-0260     Bolt     Torque to...................
22 N m (195 lb in)    
23     6I-0260     Bolt     Torque to...................
18 N m (159 lb in)    
27     6I-0260     Bolt     Torque to...................
22 N m (195 lb in)    
29     375-0351     Bolt     Torque to...................
22 N m (195 lb in)    
33     6I-4068     Bolt     Torque to...................
9 N m (80 lb in)    
37     124-3815     Bolt     Torque to...................
22 N m (195 lb in)    
38     6I-0260     Bolt     Torque to...................
22 N m (195 lb in)    
40     6I-0293     Bolt     Torque to...................
22 N m (195 lb in)    
41     6I-0293     Bolt     Torque to...................
22 N m (195 lb in)    Removal Procedure
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 g02619678
Remove clip (7) and clip (12) from tube assembly (3) and tube assembly (6) .
Remove banjo bolt (2) from tube assembly (3). Remove sealing washers (1) (not shown).
Remove banjo bolt (9) from tube assembly (6). Remove sealing washers (13) (not shown).
Remove tube assembly (6) .
remove bolt (8) from clip for tube assembly (6) .
Remove bolts (5) and bolts (11) from tube assembly (6) .
Remove tube assembly (6) from the turbo charger and the cylinder block.
Illustration 2 g02619657
Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.
Remove bolts (14) and bolts (23) from tube assembly (15) .
Remove tube assembly (15) from exhaust cooler (25) and the cylinder head.
Remove gaskets (16) (not shown) and gasket (24) (not shown) from tube assembly (15) .
Prior to and during removal of bolts (17) and bolts (29) apply releasing fluid to the bolts. Remove bolts (17) and bolts (29) from tube assembly (19) .
Remove tube assembly (19) from exhaust cooler (25) and the exhaust manifold.
Remove gaskets (18) (not shown) and gasket (28) (not shown) from tube assembly (19) .
Remove bolts (21) and bolts (27) from tube assembly (20) .
Remove tube assembly (20) from exhaust cooler (25) and the cylinder head.
Remove gasket (22) (not shown) and gasket (26) (not shown) from tube assembly (20) .
Illustration 3 g02619659
Cut cable straps (34) for wiring harness assembly (30). Ensure that all the cable straps are removed from all harness assemblies.
Slide locking tab (31) into the unlocked position. Disconnect wiring harness assembly (30) from engine wiring harness assembly (32) .
Remove bolts (33) from tube assembly (36) .
Remove bolt (37) from clamp on tube assembly (36) .
Remove bolts (38) from tube assembly (36) .
Remove tube assembly (36). Remove gasket (35) (not shown) and gasket (39) (not shown) from tube assembly (36) .
Illustration 4 g02619660
Remove bolt (40) and bolts (41) from exhaust cooler (25) .Note: The exhaust cooler should be supported as the bolts are removed.
Remove exhaust cooler (25) from the cylinder block.