859204 Volvo.Penta Engagement lever

1. Put the hood assemblies in the "OPEN" position.2. Remove bolt (1), the washers and nut. Disconnect the clip from bracket (2).3. Remove four bolts (3) and the washers.4. Remove bracket (2) from the engine. Remove pipe (4). 5. Remove two bolts (5) that secure the turbocharger tube assembly from the turbocharger.6. Loosen hose clamps (6) on both ends of the exhaust pipe. 7. Remove bolt (8) and remove exhaust pipe (7). 8. Disconnect and plug oil supply tube (9) from the cylinder block. Position the oil supply line away from the turbocharger. 9. Loosen clamp (10). Remove bolts (11) that secure the oil drain line to the turbocharger. 10. Attach a lifting sling to turbocharger (12). Secure the lifting sling to an appropriate lifting device. 11. Remove four mounting bolts (13) and remove turbocharger (12). The weight of the turbocharger group is approximately 35 kg (77 lb).12. Remove turbocharger gasket (14). The turbocharger is serviceable at the cartridge level only, or replacement of the complete turbocharger. Internal parts are not serviced. Place alignment marks on the turbocharger cartridge and housings. Alignment marks will be used during assembly.13. If necessary, loosen the V-band clamps and separate the compressor housing and the turbine housing from the turbocharger cartridge. The following steps are for the installation of the turbocharger.
Check all O-ring seals for wear or damage and replace with new parts if necessary.
If the compressor and turbine housings were separated from the turbocharger cartridge, place the components in their original position with the alignment marks. Install the V-band clamps loosely.14. Using a new gasket (14) install turbocharger group (12) on the manifold. Position the turbocharger cartridge and housings with air pipes, exhaust pipes and oil lines so they are all aligned without binding.
Do not tighten the turbocharger mounting bolts at this time.
15. Apply 5P-3931 Anti-Seize Compound to the threads of the turbocharger mounting bolts. Install turbocharger mounting bolts (13) and the nuts and washers. Tighten the turbocharger mounting bolts finger tight only.16. Position oil drain line (11) in its original location and install two bolts and the O-ring seal. Tighten the bolts finger tight only.17. Connect oil supply line (9) at the cylinder block. Position oil supply line (9) on the turbocharger. Install the two bolts and the O-ring seal. Tighten the bolts finger tight only.18. Position exhaust pipe (7) in its original location. Install two hose clamps (6) and bolt (8).19. Put a small amount of clean SAE 30W oil on the O-ring seals on pipe (4). Place pipe (4) in position on the turbocharger and the aftercooler cover.20. Place bracket (2) in position and install bolts (3). Install bolt (1) to connect the clip on the oil filler tube to the bracket.21. After all the components are positioned and aligned without binding, tighten the turbocharger V-band clamp nuts to a torque of 14 1 N m (10 1 lb ft). Tap the V-band clamps lightly all around, and tighten the V-band clamp nuts again to a torque of 14 1 N m (10 1 lb ft).22. Tighten bolts (5) and (11) to the standard torque value. Tighten turbocharger mounting bolts (13) to 55 5 N m (41 4 lb ft).23. Place the hood assemblies in the "CLOSED" position. For more detailed information regarding the turbocharger, see the topic "Turbocharger" in the Specifications Manual, SENR1017.