829903 Volvo.Penta Leak-off pipe

Illustration 1 g06458062
Follow Step 1a through Step 1h to remove and disassemble the crossover pipe assembly.
Make temporary marks on tube assembly for installation purposes only.
Sufficiently loosen hose clamp (8), position the hose clamp away from throttle valve assembly (7).
Sufficiently loosen hose clamp (4), position the hose clamp away from turbocharger (3).
Sufficiently loosen hose clamp (6), position the hose clamp away from hose (9).
Sufficiently loosen hose clamp (1), position the hose clamp away from hose (2).
Position hose (2) away from turbocharger (3).
Remove tube assembly (5) from throttle valve assembly (7).
Remove hose (9) and hose (2) from tube (5).
Illustration 2 g06458088
Cut cable strap (17) and cable strap (20).
Disconnect engine harness (18) from throttle valve (19).
Disconnect engine harness (14) from inlet manifold temperature and pressure sensor (15).
Remove nut (11) and spring washer (13) (not shown) from engine harness (12).
Remove bolts (10) from bracket (21). Remove the bracket from engine harness (12). Position the harness assembly away from inlet manifold temperature and pressure sensor (15).
If necessary, remove bolt (16) from inlet manifold temperature and pressure sensor (15). Remove the inlet manifold temperature and pressure sensor from the bracket by pulling up by hand with a slight twisting motion.Note: Do not lever the inlet manifold temperature and pressure sensor out of the bracket.Discard inlet manifold temperature sensor.
Illustration 3 g06458349
Using a suitable tool compress hose clamp (22). Position the hose clamp away from bracket (25).
Remove hose (23) from bracket (25).
Remove bolts (24) and remove bracket (25) from throttle valve assembly (7).
Remove the NOx Reduction System (NRS) cooler. Refer to Disassembly and Assembly, "Exhaust Cooler (NRS) - Remove and Install" for the correct procedure.
Illustration 4 g06458712
Remove temperature sensor (26) from the cylinder head. Remove O-ring (27) (not shown).Installation Procedure
Note: Remove all plugs and caps as installation is completed.
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Illustration 5 g06458712
Install new O-ring (27) (not shown) to temperature sensor (26).
Install temperature sensor (26) to the cylinder head. Loosely tighten the temperature sensor.
Tighten temperature sensor (26) to a torque of 17 N m (150 lb in).
Install the NRS cooler. Refer to Disassembly and Assembly, "Exhaust Cooler (NRS) - Remove and Install" for the correct procedure.
Illustration 6 g06458349
Position bracket (25) onto throttle valve assembly (7). Install bolts (24). Loosely tighten the bolts.
Tighten bolts (24) to a torque of 22 N m (195 lb in).
Use a suitable tool to expand new hose clamp (22) and move the hose clamp along hose (23) towards bracket (25).Note: Ensure that the hose clamp is correctly orientated.
Illustration 7 g06458088
If necessary, Install new inlet manifold temperature and pressure sensor (15). Ensure that the inlet manifold temperature and pressure sensor is correctly installed to bracket (25).
Install bolt (16) to new inlet manifold temperature and pressure sensor (15). Loosely tighten the bolt.
Tighten bolt (16) to 8 N m (71 lb in).
Position bracket (21) onto engine harness (12). Install bolts (10). Loosely tighten the bolts.
Tighten bolts (10) to a torque of 22 N m (195 lb in).
Install spring washer (13) and nut (11) onto engine harness (12). Loosely tighten the nut.
Tighten nut (11) to a torque of 8 N m (71 lb in).
Connect engine harness (14) to inlet manifold temperature and pressure sensor (15).
Connect engine harness (18) to throttle valve (19).
Install new cable strap (17) and new cable strap (20).Note: Ensure that the cable straps meet the OEM specification.
Illustration 8 g06458062
Follow Step 19a through Step 19h to install and assemble the crossover pipe assembly.
Position hose (9) and hose (2) onto tube (5) in the positions noted on the removal.
Position new hose clamp (8), new hose clamp (6), new hose clamp (1), and new hose clamp (4) onto tube assembly (5).Note: Ensure that the hose clamps are correctly orientated.
Install hose assembly (5) onto throttle valve assembly (7) and turbocharger (3).
Position new hose clamp (8) onto hose (9) in the position noted on the removal. Loosely tighten the hose clamp.
Position new hose clamp (6) onto hose (9) in the position noted on the removal. Loosely tighten the hose clamp.
Position new hose clamp (4) onto hose (2) in the position noted on the removal. Loosely tighten the hose clamp.
Position new hose clamp (1) onto hose (2) in the position noted on the removal. Loosely tighten the hose clamp.
Tighten all hose clamps to a torque of 4.5 N m (40 lb in).