3854096 Volvo.Penta Intake gasket kit

1. Drain the cooling system. 2. Remove brace (1).3. Disconnect the governor control linkage from the governor. Remove the bolts that hold control channel (2) in place and move the control channel clear of the aftercooler housing.4. Disconnect lines (3) and (4) from the block. 5. Remove bolt (5) and the washer that hold air inlet elbow (7) to the turbocharger. Disconnect equalizer line (6) from the inlet elbow and remove bolts (8). Remove inlet elbow (7).6. Remove water line (9). 7. Remove bracket (10).8. Remove aftercooler water outlet elbow (12) from the rear of the aftercooler lower housing. Pull sleeve (11) out of the aftercooler core. 9. On left aftercooler only remove bolt (13) and brace (16).10. Remove aftercooler water inlet elbow (15). Pull sleeve (14) out of the aftercooler core.11. To remove the left aftercooler core only, disconnect three gauge lines (17). Remove the instrument panel mounting bolts and move the instrument panel clear of the aftercooler. 12. Remove clip (18). Remove the bolts that hold bracket (19) for the safety alarm contactor to the aftercooler housing. Move the safety alarm contactor clear of the aftercooler.13. Remove brace (20). 14. Fasten tooling (A) and a hoist to upper housing (21). Remove the bolts that hold the housing in place and remove the upper housing. Weight is approximately 62 lb. (28 kg). 15. Fasten a hoist and remove aftercooler core (22). Weight is approximately 76 lb. (34 kg). 16. Remove thermocouple adapter (23) from the lower housing. Remove contactor (24) from the lower housing.17. Fasten tooling (A) and a hoist to housing (25). Remove the bolts that hold the lower housing in place and remove the housing. Weight is approximately 80 lb. (36 kg).Install Aftercooler Cores And Housings (Later Engine)
1. Thoroughly clean the contact surfaces of the aftercooler core and the upper and lower housings. 2. Fasten tooling (A) and a hoist to aftercooler lower housing (1). Put the gasket and aftercooler lower housing in position on the engine. Weight is approximately 80 lb. (36 kg). Install the bolts that hold the housing in place. 3. Install thermocouple (2) and contactor (3) in the lower housing. 4. Install a new gasket between the core and lower housing. Fasten a hoist and install aftercooler core (4) into the lower housing. 5. Install a new gasket between the core and upper housing. Fasten tooling (A) and a hoist to upper housing (5). Put the housing in position and install the bolts that hold it in place.
Be sure the drain hole in the sleeves is down when the sleeves are installed.
6. Install sleeves (6) in the front and rear of the aftercooler lower housing. 7. Put water outlet elbow (7) in position on the rear of the aftercooler housing and install the bolts that hold it in place. Install the bracket between the water outlet elbow and the turbocharger heat shield. Install the water line on the turbocharger heat shield.8. Put bracket (8) for the safety alarm contactor in position and install the bolts that hold it in place. Install the clip on line (9). 9. Put the instrument panel in position on the left aftercooler housing and install the bolts that hold it in place. Connect lines (10) to the block.10. Install aftercooler water inlet elbow (13) on the front of the aftercooler housing. 11. Install brace (12) and clip (11) as shown. 12. Put air inlet elbow (14) in position. Install bolts (15) and bolt and washer (17) to hold the elbow in place. Install equalizer line (16) and the gaskets.13. Install bolt (19).14. Connect lines (21) and (22) to the block. 15. Put governor control channel (18) in position and install the bolts and spacers to hold it in place. Connect the governor control linkage to the governor.16. Install brace (20).17. Fill the cooling system to the correct level with coolant.