3828447 Volvo.Penta Engine heater

Table 1
Required Tooling
Tool Part Number Part Description Qty
A 138-7575 Link Brackets 2
B - Loctite Nickel Anti Seize 1
Illustration 1 g03017997
Apply Tooling (B) to the T-bolt threads of strap assemblies (22) from the trunnion face to a length of 25 mm (1.0 inch).
Install clean emissions module (23). Install strap assemblies (22). Tighten strap assemblies (22) to a torque of 15 + 3 - 0 N m (133 + 27 - 0 lb in). Repeat this step for the remaining clean emissions module .
Illustration 2 g03017996
Install heat shields (21).
Illustration 3 g03017596
Attach a suitable lifting device to exhaust module (19). The weight of exhaust module (19) is approximately 195 kg (430 lb). Use the suitable lifting device in order to position exhaust module (19) to the machine.
Illustration 4 g03017736
Install bolts (20) on both sides of the machine in order to secure exhaust module (19) to the machine.
Illustration 5 g03018977
Illustration 6 g03018638
The protective wrap is not shown for photographic purposes.
(13) Bellows
(16) Exhaust line
Install new clamp (14) with the tightening assembly centered as shown in Illustration 5. Do not torque the clamp until Step 17. Note: The end of the clamp must be flush with the end of the bellows assembly.
Distance (X) is 40 mm (1.6 inch). Place Mark (C) onto exhaust line (16) at Distance (X) from the end of exhaust line (16).
Insert exhaust line (16) into bellows (13). Exhaust line (16) should be inserted as far as possible without using force. This action will minimize the overall length of the lines group and will help with installation.
Illustration 7 g03024118
Example of configuration with the bellows located near the CEM inlet
Prior to installation, position both ball clamp assemblies (12) and (17) onto the lines group.
Position the lines group between the muffler and converter assembly and the turbocharger adapter. Adjust the length of exhaust line (16) in slip joint clamp (14) in order to position the lines group. Note: Do not force any of the components into the position.Note: Make sure that you loosely fit all of the parts before the final torquing is started.Note: Failure to reinstall the bellows into the original alignment will result in a failure of the part and a needed replacement.
Illustration 8 g03020560
Typical ball joint alignment
Verify that the cup of the ball joint (E) does not touch the radius of the ball (D). Position ball clamp (17) and loosely tighten ball clamp (17).
Illustration 9 g03024124
Example of configuration with the bellows located near the CEM inlet
Note: The ball clamp that is opposite the bellows must always be tightened first. Ball clamp (17), which can be located at the turbocharger diffuser outlet must be tightened first. Refer to Illustration 9 for example of the possible placement of clamp (17).
Verify that the ball clamp is centered. Measurement (Y) and measurement (Z) must be within 2.0 mm (0.08 inch) of each other. Refer to Illustration 8.
Repeat Steps 11 and 12 for ball clamp (12).
Verify that Mark (C) in Illustration 6 is not visible at the slip joint that is positioned near slip joint clamp (14). Note: Torque the clamps on Steps 15 through 17 with a maximum wrench speed of 75 RPM if hand tools are not used.
Torque ball clamp (17) to a torque of 35 2 N m (26 1 lb ft).
Torque ball clamp (12) to a torque of 35 2 N m (26 1 lb ft).
Torque slip joint clamp (14) to a torque of 55 8 N m (41 6 lb ft).
Remove the protective cover that was installed in Step 6 of the removal section.