3812484 Volvo.Penta O-ring

1. Put the turbocharger in position on tool group (A) as shown. Put alignment marks on the three housings of the turbocharger for correct installation and alignment at assembly.2. Remove the bolts, and remove adapter (1) from the turbine housing. 3. Install a 3/8"-16 NC bolt and a nut (3) in the turbine housing.4. Install a 10 mm Allen Wrench (2) in the end of the turbine shaft. The bolt and wrench will hold the turbine shaft in place when the nut that holds the compressor wheel is loosened.
To prevent a bent shaft, do not put a side force on the turbine shaft when the compressor nut is loosened.
5. Use a universal joint and a 22 mm socket (4) to loosen the nut that holds the compressor wheel to the turbine shaft. 6. Move the turbocharger with tool group (A) to the position as shown. Remove bolts (6) and the clamps to remove compressor housing (5) from the cartridge group. 7. Remove diffuser (7) from the cartridge group.8. Bend the locks away from bolts (8). Remove bolts (8) and the clamps to remove the cartridge group from the turbine housing. 9. Remove retainer ring (9) and turbine nozzle (10) from the turbine housing.10. Remove the nut from the end of the turbine shaft. 11. Use a press to remove the turbine shaft from compressor wheel (11) and the cartridge group. Remove compressor wheel (11) from the cartridge housing. 12. Remove heat shrouds (14) and (15) from turbine shaft (12).13. Remove seal ring (13) from turbine shaft (12). 14. Remove seal carrier ring (16) from the compressor insert. 15. Remove compressor seal ring (17) from the compressor insert. 16. Use tool (B) to remove snap (18) that holds the compressor insert in the cartridge housing. 17. Use two screwdrivers to remove compressor insert (19) from the cartridge housing. Remove the O-ring seal from the compressor insert. 18. Remove thrust ring (20) from thrust bearing (21).19. Remove the bolts, and remove thrust bearing (21) from the cartridge housing. 20. Remove inboard thrust ring (22) from the cartridge housing. 21. Use tool (C) to remove snap ring (23) that holds journal bearing (24) in place.22. Remove journal bearing (24) from the cartridge housing. 23. Use tool (C) to remove snap ring (25) from the cartridge housing. 24. Use tool (C) to remove snap ring (26) that holds journal bearing (27) in the turbine end of the cartridge housing.25. Remove journal bearing (27) from the cartridge housing. 26. Use tool (C) to remove snap ring (28) from the cartridge housing.Assemble Turbocharger
1. Clean and inspect all parts of the turbocharger. Make replacements of any worn or damaged parts. Make sure the oil passages in the cartridge housing and journal bearings are open and free of foreign material.2. Put clean engine oil on all parts of the cartridge group at assembly. Make sure the round edge on the outside diameter of the snap rings are toward the journal bearings when the snap rings are installed. 3. Use tool (A) to install snap ring (1) in the turbine end of the cartridge housing. 4. Install journal bearing (2) in the cartridge housing. 5. Use tool (A) to install snap ring (3) to hold the journal bearing in position.
The journal bearings must turn freely after installation.
6. Use tool (A) to install snap (4) in the compressor end of the cartridge housing. 7. Install journal bearing (5) in the cartridge housing. 8. Use tool (A) to install snap ring (6) to hold the journal bearing in position. 9. Install inboard thrust ring (8) in the cartridge housing. Ring (8) can be installed with either side down.10. Install thrust bearing (7) and the bolts to hold it in the cartridge housing. Tighten the bolts evenly to a torque of 10 2 N m (89 18 lb.in.). 11. Install thrust ring (9) in the thrust bearing. 12. Install O-ring seal (11) on compression insert (10).13. Install compressor insert (10) in the cartridge housing. Make sure the bevel side of the snap ring is up. 14. Use tool (B) to install snap ring (12) to hold the compressor insert in position. 15. Install compressor seal ring (13) in the compressor insert. 16. Install seal carrier ring (14) in the compressor insert. Make sure the carrier ring is inside the compressor seal ring. 17. Put 6V2055 High Vacuum Grease in the groove for seal ring (16). Make sure the grease fills the groove approximately one half or more of the groove depth for the complete circumference of the groove to help make a carbon dam under the seal ring. Install seal ring (16) on turbine shaft (15). 18. Install heat shrouds (18) and (17) on the turbine shaft. 19. Install cartridge group (19) over the turbine shaft. Make sure the seal ring on the turbine shaft is fitted correctly in the cartridge group. 20. Put compressor wheel (20) in position on the turbine shaft.21. Put a small amount of 2P2506 Thread Lubricant on the threads of the turbine shaft and on the compressor wheel face that will be under the nut and washer. Install the washer and nut on the turbine shaft, but do not tighten the nut at this time. 22. Install turbine housing (23) on tool group (D) as shown.23. Install turbine nozzle (22) and retainer ring (21) in the turbine housing. Make sure the turbine nozzle is in alignment with the three notches in the turbine housing. If the turbine nozzle is not in alignment, loss of inlet manifold pressure (boost) will result. 24. Put cartridge group (19) in position in the turbine housing. Make sure the marks on the housing and cartridge are in alignment.25. Put 5P3931 Anti-Seize Compound on the threads of the bolts. Install the clamps, locks and bolts to hold the cartridge group in the turbine housing. Tighten the bolts to a torque of 48 3 N m (35 2 lb.ft.), and bend the tabs of the locks on the