77747 Volvo.Penta Field winding

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g06537710
Typical Example
Disconnect Original Engine Manufacturers (OEM) exhaust from turbocharger assembly (5).
Follow Step 2a through Step 2d to remove cross over pipe assembly (1).
Using a suitable tool, loosen hose clamp (4) and position the hose clamp away from turbocharger (5).Note: Note hose clamp position and orientation for installation purposes.
Using a suitable tool, loosen hose clamp (2) and position the hose clamp away from hose (3). Reposition the hose away from turbocharger (5)Note: Note hose clamp and hose position and orientation for installation purposes.
Using a suitable tool, loosen hose clamp (8) and position the hose clamp away from air inlet elbow (9).Note: Note hose clamp position and orientation for installation purposes.
Using a suitable tool, loosen hose clamp (6) and position the hose clamp away from hose (7). Reposition the hose away from air inlet elbow (9). Remove cross over pipe assembly (1).Note: Note hose clamp and hose, position, and orientation for installation purposes. Remove cross over pipe assembly (1)
Illustration 2 g06537787
A high proportion of engine oil will be removed from the blow-by gas by the oil separator in the valve mechanism cover. In a closed breather system, the presence of some oil in the breather connection to the air induction systems and downstream of the compressor in air to air charge cooler connections after service is to be expected.
Remove connector (10) from valve mechanism cover (16) and remove connector (12) from breather heater assembly (15). Remove breather tube assembly (11).
Loosen hose clamp (13) and remove inlet tube assembly (14) from turbocharger (5).
Illustration 3 g06538074
Typical Example
Remove banjo bolt (19) from tube assembly (21). Remove O-ring seal (20) (not shown) and O-ring seal (22) (not shown) from the tube assembly.
Position tube assembly (21) away from turbocharger (5).
Loosen bolts (17) and remove heat shield (18).
Remove bolts (17) from the cylinder head.Note: Note bolt position for installation purposes.
Remove Allen head bolts (28) from the oil drain pipe (27).
Loosen bolts (24) from turbocharger (5).
Support adapter (23) and remove bolts (24). Remove gasket (25) (not shown).
Illustration 4 g06538080
Typical Example
Remove nuts (30) from turbocharger (5).
Remove turbocharger (5) from exhaust manifold (29).
Remove gasket (31) (not shown) from turbocharger (5).
Remove bolts (32) and remove tube assembly (27) from the cylinder block.Note: Note tube assembly position and orientation for installation purposes.
Remove gasket (26) (not shown) and gasket (33) (not shown) from tube assembly (27).
Illustration 5 g06538082
Typical Example
Remove stud (34) and studs (35) from turbocharger (5).
If necessary, remove fuel pressure regulator. Refer to , "Fuel Pressure Regulator - Remove and install" for the correct procedure.
Remove the air inlet elbow. Refer to Disassembly and Assembly, "Air Inlet Elbow - Remove and Install" for the correct procedure.
If necessary, remove the pump to rail fuel injection line. Refer to , "Fuel Injection Lines - Remove" for the correct procedure.
Illustration 6 g06538083
Typical Example
If necessary, follow step 21a through 21c to remove engine harness to allow removal of turbo oil feed line (21)
Cut cable strap (50), cable strap (49), and cable strap (48).
Disconnect engine harness (44) from fuel temperature sensor (45).
Disconnect engine harness (46) from flow control valve (47).
If necessary, follow step 22a through 22e to remove tube assembly (21)
Remove bolt (36) and bolt (38) from the pipe clamps on tube assembly (21).Note: Note bolts position for installation purposes.
Position pipe clamp (37) away from valve mechanism cover (16) and pipe clamp (39) away from the engine cylinder head.Note: Note pipe clamps position and orientation for installation purposes.
Remove tube nut (43) from adaptor (41) and remove tube assembly (21).Note: Note tube position and orientation for installation purposes.
Remove O-ring seal (42) (not shown) from adaptor (41).
Remove adaptor (41) from the oil filter head, remove O-ring seal (40) (not shown) from the adaptor.