242079 Volvo.Penta Lever

Illustration 1 g06463803
If the Diesel Particulate Filter (DPF) assembly is mounted on the valve mechanism cover, removal of the DPF assembly will be necessary to access the wastegate solenoid. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Remove" for the correct procedure.
Loosen hose clamps and remove hose assembly from inlet elbow (6).
Follow Step 3a through Step 3d to remove the crankcase breather tube assembly.
Cut cable strap (3).
Disconnect crankcase breather hose assembly connection (2) from valve mechanism cover connection (1).
Disconnect crankcase breather hose assembly connection (5) from crankcase breather canister (4).
Remove the crankcase breather hose assembly from the engine.
Slide the locking tab into the unlocked position. Disconnect harness assembly (9) from the harness assembly for wastegate solenoid (7).
Slide the harness assembly for wastegate solenoid (7) from bracket (8).
Illustration 2 g06463817
Using a suitable tool, position hose clamp (11) away from turbocharger wastegate (12). Disconnect hose (10) from the turbocharger wastegate.
Illustration 3 g06464104
Remove banjo bolt (15) and remove sealing washer (13) (not shown) and sealing washer (14) (not shown).
Remove bolt (17) from pipe clamp (18).
Remove bolt (20) from pipe clamp (19).
Remove bolt (22) from pipe clamp (21).
Cut cable strap (18A). Remove pipe assembly (16) from the engine.
Illustration 4 g06464132
If necessary, follow Step 12a through Step 12g to disassemble pipe assembly (16).
Make temporary marks on pipe assembly (16) for installation purposes only.
Using a suitable tool position hose clamp (26) away from pipe assembly (16).
Remove pipe assembly (16) from hose (25).
Using a suitable tool position hose clamp (27) away from pipe assembly (24).
Remove hose (25) from pipe assembly (24).
Using a suitable tool position hose clamp (23) away from pipe assembly (24).
Remove pipe assembly (24) from hose (10).
Illustration 5 g06464119
Illustration 6 g06464127
Remove bolts (30) and bracket (8) from inlet elbow (6).
Remove wastegate solenoid (7) from inlet elbow (6).
Support inlet elbow as bolts (28) are removed. Remove the bolts and gasket (29) (not shown) from the NRS induction mixer assembly.Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Delphi Lockheed Rubber Grease 1
Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness and the convoluting.
Ensure that all components of the wastegate solenoid are clean and free from wear and damage. If necessary, replace the wastegate solenoid as an assembly if any of the components are worn or damaged.
Illustration 7 g06464119
Illustration 8 g06464137
Position gasket (29) (not shown) on to the NOx Reduction System (NRS) induction mixer assembly.
Install bolts (28) to inlet elbow (6). Install the inlet elbow to the NRS induction mixer assembly. Hand tighten the bolts.
Tighten bolts (28) to a torque of 22 N m (195 lb in).
Ensure that O-ring seal (31), and O-ring seal (32), on wastegate solenoid (7) are free from damage and wear.
If the O-ring seals are damaged or worn, the wastegate solenoid should be replaced as an assembly.
Ensure that the ports in Position (X) are clean and free from restriction.
Remove the cap from wastegate solenoid (7) and remove plug from inlet connection (6).
Use Tooling (A) to lubricate O-ring seal (31), and O-ring seal (32) on wastegate solenoid (7).
install wastegate solenoid (7) to inlet connection (6).
Position bracket (8) onto wastegate solenoid (7).Note: Ensure that the bracket is correctly orientated.
Install bolts (30) to wastegate solenoid (7). Tighten the bolts to a torque of 9 N m (80 lb in).
Illustration