3848813 Volvo.Penta Manifold

Engine
Steam Clean
Accumulated grease and oil on an engine is a fire hazard. Keep your engine clean. Remove debris and fluid spills each time a significant quantity accumulates on the engine.
Steam cleaning the engine is a recommended preventive maintenance practice. It provides for easy detection of oil and coolant leaks. Repairing an oil or coolant leak upon detection may save money by avoidance of major repairs that could result from low oil or coolant levels.Steam cleaning the engine as recommended will also improve the engine's heat transfer characteristics which can improve engine efficiency.Turbocharger
Inspect/Check
1. Remove the exhaust outlet piping and inlet piping from the turbocharger.2. Turn the turbine and compressor wheel by hand.3. The assembly should turn freely.4. Inspect the turbine wheel and compressor wheel for contact with the turbocharger housing.5. There should NOT be any visible signs of contact between the turbine or compressor wheel and the turbocharger housing. When installing or replacing V-band clamps, position the gap (tightening screw) down if possible so any water will drain away.6. Visually check for oil leaks.
Turbocharger bearing failures can cause large quantities of oil to enter the air intake and exhaust systems. Loss of engine lubricant can result in serious engine damage. Minor leakage of a turbocharger housing under extended low idle operation will not cause problems as long as no turbocharger bearing failure occurred.When a turbocharger bearing failure is accompanied by a significant engine performance loss (exhaust smoke or engine speed up at no load), DO NOT continue engine operation until the turbocharger is repaired or replaced.
If maintenance is required, refer to PM Level 3 in this publication for turbocharger service options.Engine Mounts
Inspect/Check
Front engine mount shown.Caterpillar recommends inspecting the engine mounts for proper bolt torque. This will prevent excessive engine vibration caused from deterioration and/or improper mounting. See your Service Manual or OEM truck manufacturer for recommended torque values.Vibration Damper
Inspect/Check
Damage to, or failure of, the damper will increase torsional vibrations and result in damage to the crankshaft and other engine components. A deteriorating vibration damper will cause excessive gear train noise at variable points in the speed range. The vibration damper can have a visual wobble (movement to the front and rear when in rotation) on the outer ring. This does not mean a replacement is necessary since some wobble of the outer ring is normal. To see if the amount of wobble is acceptable, or replacement is necessary, check the damper with the procedure in the Testing and Adjusting section of the Service Manual.The vibration damper has marks on the hub (1) and ring (2). These marks will indicate the condition of the vibration damper. If the marks are not in alignment, the rubber seal (3) between the ring and the hub has separated from the ring and/or hub. If the marks are not in alignment, install a new vibration damper.Air Compressor
Inspect/Check
Do not disconnect the air line from the air compressor governor without purging the air brake and auxiliary air systems. Failure to purge the air brake and auxiliary air systems before removing the air compressor could cause personal injury.
1. Release the air pressure in the air tank until the air pressure is zero. 2. Remove discharge fittings and inspect compressor discharge port and discharge line for excessive carbon deposits. The discharge line must be cleaned or replaced and the compressor checked more thoroughly if there is excessive carbon build-up in either the discharge line or compressor discharge port.For more information on how to check your air compressor, refer to the Service Manual for this engine.Thermostat
Replace Thermostat, Gaskets and Seal
Replacing your thermostat prior to failure is a recommended preventive maintenance practice because it reduces the chances for unscheduled downtime. Failure to replace the thermostat on a regularly scheduled basis could cause severe engine damage and added cost because of damage to other engine components.Since Caterpillar engines incorporate a shunt design cooling system, it is mandatory to always operate the engine with a thermostat.Depending on load, a thermostat that fails in a partially opened position will cause either an overheating or an overcooling condition.If the thermostat fails in the closed position, it will cause excessive overheating. Excessive overheating could result in cylinder head cracking or piston seizure problems.If the thermostat fails in the open position, it will cause the engine operating temperature to be too low during partial load operation. Low engine operating temperatures during partial loads could cause an excessive carbon build-up inside the cylinder. This excessive carbon build-up could result in accelerated ring and liner wear.Caterpillar recommends the replacement of the thermostat on a regularly scheduled basis to be the most cost effective way to operate an engine. All tools shown or mentioned in the following Disassembly and Assembly procedure are available at any Caterpillar dealer.Remove Thermostat
1. Stop the engine and allow to cool. Loosen the coolant filler cap slowly to relieve any pressure and remove the cap.2. Drain the coolant from the cooling system to a level below the thermostat housing. 3. Remove six bolts (1) that fasten the thermostat housing to the cylinder head and remove thermostat housing (2) and gaskets. 4. Remove thermostat (3) from the housing. The thermostats can be reused if they are tested and meet the test specifications below and are not damaged or have excessive buildup of deposits.Thermostats should begin to open and be fully open as indicated in the following chart: 5. Remove lip-type seal (4) from the housing. Use tooling [Slide Hammer Puller (1P0074), Bearing Cup Puller Attachment (8B7554) and Leg (7S7786)] to remove seal from the housing.6. Replace thermostat, gaskets and seal.Install Thermostat
7. Install lip-type seal (1) in housing with tooling (A) [Driver Group (1P0510)]. Install the seal with the