842695 Volvo.Penta Gaiter

Note: The following clamps and bellows are one-time use components. Discard the components after removal and install new components.
Illustration 1 g02790637
Engine was not illustrated for photographic purposes.
Note: Note the orientation of clamps (2). If installed incorrectly, the clamps will damage the heat shields.
Loosen clamps (2). Remove bolts (4) and any spacers.
Remove exhaust manifold (3) and remove bellows (1) and the gaskets. Remove gasket (5) from exhaust manifold (3).
Repeat Step 1 and Step 2 for the next four exhaust manifolds. Repeat for the other side.
Illustration 2 g02790688
Engine was not illustrated for photographic purposes.
Note: Note the orientation of clamps (8) and (11). If installed incorrectly, the clamps will damage the heat shields.
Loosen clamps (11) and (8). Remove bolts (13) and any spacers.
Remove exhaust manifold (12). Remove bellows (9) and (10) and the gaskets. Remove gasket (14) from exhaust manifold (12).Note: The only gasket for bellows (10) will be located on the exhaust manifold side of the bellows. Note the orientation of bellows (10) for installation. The air flow direction is from the exhaust manifold to the turbocharger.
Repeat Step 4 and Step 5 for the other side.Note: Some engine arrangements are equipped with a cap in place of adapter (7) for the exhaust bypass valve. If so, the following step can be ignored.
Remove bolts (6) and adapter (7). Remove the gasket from adapter (7).Installation Procedure
Note: The following clamps and bellows are one-time use components. Discard the components after removal and install new components.
Illustration 3 g02790688
Engine was not illustrated for photographic purposes.
Note: Some engine arrangements are equipped with a cap in place of adapter (7) for the exhaust bypass valve. If so, the following step can be ignored.
Position adapter (7) and install bolts (6). Tighten bolts (6) to a torque of 55 5 N m (41 4 lb ft).Note: Clamps (11) and (8) are to be orientated horizontally with the threaded rods pointing outward from the engine. Note the orientation noted when removed.Note: Ensure that the gaskets for bellows (9) and (10) are seated correctly with the tabs properly positioned. If the gaskets slide out of position, check that section of the exhaust manifold for damage and replace if there is damage.
Install the gaskets for bellows (9) and (10) and install bellows (9) and (10). Position clamps (11) and (8) horizontally.Note: Note the orientation of bellows (10) with the direction of air flow.
Seat gasket (14) onto exhaust manifold (12). Install exhaust manifold (12).
Install the spacers and bolts (13). Tighten to a torque of 55 5 N m (41 4 lb ft). Retighten to a torque of 55 5 N m (41 4 lb ft).
Check the final position of clamps (8) and (11). Tighten clamps (11) to a torque of 7.5 1 N m (66.38 8.85 lb in). Tighten clamps (8) to a torque of 17 2 N m (150.5 17.7 lb in).
Repeat Step 2 through Step 5 for the other side.
Illustration 4 g02790637
Engine was not illustrated for photographic purposes.
Note: Clamps (2) are to be orientated horizontally with the threaded rods pointing outward from the engine. Note the orientation noted when removed.Note: Ensure that the gaskets for bellows (1) are seated correctly with the tabs properly positioned. If the gaskets slide out of position, check that section of the exhaust manifold for damage and replace if there is damage.
Seat gasket (5) onto exhaust manifold (4).
Position exhaust manifold (4). Install the spacers and bolts (4). Tighten to a torque of 55 5 N m (41 4 lb ft). Retighten to a torque of 55 5 N m (41 4 lb ft).
Check the final position of clamps (2). Tighten clamps (2) to a torque of 12 N m (106 lb in).
Repeats Step 7 through Step 9 for the remaining exhaust manifolds. Repeat for the other side.
Refer to the following checks after installation:
Confirm that all the clamps are orientated horizontally and the rods pointing outwards from the engine.
Confirm that each clamp has a uniform gap. If not, ensure that the gasket for each joint is seated correctly.
Check that the bellows are aligned correctly.
Use the above procedures to correct any issues that are found in the above checks.End By:
Install the air inlet manifold. Refer to Disassembly and Assembly, "Air Inlet Manifold - Remove and Install".