963104 Volvo.Penta Lock nut

1. Remove bolts (2) and remove elbow (1) and the pipe from the turbocharger. 2. Fasten a hoist to exhaust elbows (4). Remove bolts (5) and (7) and remove the elbows and coupling from the machine as a unit. Weight of the unit is 102 lb. (46 kg).3. Disconnect oil supply line (3) from the top of the turbocharger and the cylinder block. Remove the bolt from the clip that holds the oil supply line and remove oil supply line (3) from the machine.4. Disconnect oil drain line (6) from the turbocharger and flywheel housing. Remove oil drain line (6) from the machine. 5. Fasten a hoist to turbocharger (8). Remove the bolts (9) and nuts that hold the turbocharger to the exhaust manifold.6. Remove the turbocharger (8). Weight of the turbocharger is 56 lb. (25 kg).Install Turbocharger
1. Put clean SAE 30 oil on the seals for pipe (2). Install the pipe in the turbocharger.2. Fasten a hoist to turbocharger (1) and put it in position on the engine. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold the turbocharger to the exhaust manifold. Install the bolts and tighten the nuts to a torque of 40 4 lb.ft. (55 5 N m). 3. Install oil drain line (4) and gaskets between the turbocharger and flywheel housing.4. Install oil supply line (3) and the gasket. 5. Fasten a hoist to exhaust elbows (5) and put them in position on the engine. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold the exhaust elbows. Install the bolts and nuts. If the bracket was removed from the exhaust elbow make sure nuts (6) are tightened to a torque of 20 3 lb.ft. (25 4 N m). 6. Put clean SAE 30 oil on the seals for pipe (8) and install the pipe in elbow (7).7. Put elbow (7) in position and install the bolts and washers to hold it in position.end by:a) install air cleaner assemblyb) install mufflerDisassemble Turbocharger Schwitzer
start by:a) remove turbocharger 1. Install turbocharger in tool group (A). Put marks on the three housings of the turbocharger for correct installation and alignment at assembly. Remove "V" clamp (2) and compressor housing (1). 2. Remove "V" clamp (3). Remove the cartridge housing (5) from the turbine housing (4). 3. Put the cartridge assembly in tool (B) as shown.4. Use tool (C) and remove the nut that holds compressor wheel (6). Remove compressor wheel (6).
When the nut is loosened, do not put a side force on the shaft.
5. Remove the turbine shaft (7) from the cartridge housing. 6. Remove seal ring (9) and shroud (8) from turbine shaft (7). 7. Use tool (D) and remove ring (11) that holds insert (10) in the cartridge housing. 8. Remove insert (10) with tooling (E). 9. Remove O-ring seal (13) and sleeve (12) from insert (10). Remove the seal ring from sleeve (12). 10. Remove deflector (14) and the ring from the cartridge housing. 11. Remove bearing (15), sleeve (16) and the ring from the cartridge housing. The oil hole in bearing (15) must be open or a bearing failure will be the result. 12. Use tool (F) and remove the ring that holds bearing (17) in position. Remove bearing (17) and put a long dye mark on the top face of the bearing. 13. Turn the cartridge assembly over. Use tool (F) and remove the ring that holds bearing (18) in position. Remove bearing (18) from the cartridge housing. Put a short dye mark on the top face of bearing (18). The dye marks are used for identification of the bearings when they are installed.14. If necessary, remove the two rings that hold the bearings in position from the cartridge housing with tool (F).15. Check all the parts of the turbocharger for damage. If the parts have damage, use new parts for replacement. See SPECIAL INSTRUCTION FORM NO. SMHS6854 for TURBOCHARGER RECONDITIONING. Also see GUIDELINE FOR REUSABLE PARTS FORM NO. SEBF8018 and ANALYZING TURBOCHARGER FAILURE FORM NO. FEG45138.Assemble Turbocharger Schwitzer
1. Make sure all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material.2. Put clean engine oil on all parts of the cartridge assembly.3. Make a replacement of the two inside rings that hold the bearings in position in the cartridge housing if necessary. Install the rings that hold the bearings in position with the round edges of the rings toward the bearings. 4. Install bearing (2) in the cartridge housing with with the short dye mark up.5. Use tool (A) to install ring (1) in the cartridge housing. 6. Turn the cartridge assembly over and install bearing (4) with the long dye mark up. Use tool (A) and install ring (3) to hold the bearing in position. 7. Install ring (7), sleeve (6) and bearing (5) in the cartridge housing. Make sure the oil hole in bearing (5) is open and clean to prevent a bearing failure. 8. Install ring (9) and deflector (8) in the cartridge housing. 9. Install O-ring seal (12) around insert (11).10. Install the seal ring on sleeve (10). 11. Install sleeve (10) in insert (11) from the bottom side.12. Install insert (11) in the cartridge housing. Use tool (B) and install the ring to hold the insert in position. Put 6V2055 High Vacuum Grease in the groove for seal ring (15) at assembly to one half or more of the depth of the groove all the way around.13. Install seal ring (15) and shroud (13) on turbine shaft (14). 14. Put the turbine shaft in tool (C) and install the cartridge housing on turbine shaft (14). Make sure seal ring (15) is fitted correctly in the cartridge housing.15. Put 6V1541 Primer on the nut and turbine shaft threads to remove any oil or grease.
Do not let the retaining compound get into the compressor wheel bore, because it can make removal of the compressor wheel difficult during future turbocharger disassembly.
16.