877078 Volvo.Penta Overhaul kit

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Remove all of the plastic plugs from all of the ports of the turbocharger (1). Clean the mating surfaces of the exhaust manifold and the turbocharger. Clean the mating surfaces of the turbocharger to the oil supply tube assembly (6) and the turbocharger to the oil drain tube assembly (9).
Ensure that all of the turbocharger inlet and outlet ports are clean and free from restrictions. The turbocharger shaft must rotate freely.
Illustration 1 g01038396
Typical example
If the studs (15) were previously removed, install the studs into the exhaust manifold. Install a new gasket (14) over the studs (15). Note: Do not use any sealant on the gasket (14).Note: Do not use the actuator rod of the wastegate (16) to lift the turbocharger (1).
Position the turbocharger (1) onto the exhaust manifold.
Install the nuts (13). Tighten the nuts (13) to a torque of 47 N m (35 lb ft).
Lubricate the bearing housing of the turbocharger (1) with clean engine oil.
Inspect all of the oil hose assemblies (6 and 9). If necessary, replace the hose assemblies (6 and 9). Note: The top flange of the oil drain tube assembly (9) is secured to the turbocharger (1) with 6 mm setscrews (8). The bottom flange of the oil drain tube assembly (9) is secured to the cylinder block with 8 mm setscrews (11).
Position a new joint (10) and the oil drain tube assembly (9) onto the bottom of the turbocharger (1). Install the 6 mm setscrews (8). Tighten the 6 mm setscrews (8) to a torque of 9 N m (80 lb in).
Position a new joint and the oil drain tube assembly (9) onto the cylinder block. Tighten the 8 mm setscrews (11) to a torque of 22 N m (16 lb ft).
Position the new washers (7) and the oil supply tube assembly (6) onto the turbocharger (1). Install the banjo bolt (5). Tighten the banjo bolt (5) to a torque of 22 N m (16 lb ft). Note: Ensure that the oil supply tube assembly (6) does not come into contact with any other component when the assembly is installed onto the engine.
Install the new washers and the oil supply tube assembly (6) to the cylinder block. Tighten the banjo bolt to a torque of 22 N m (16 lb ft).
If the studs (12) were previously removed, install the studs into the turbocharger housing.
Illustration 2 g01038406
Typical example
Position the exhaust adapter (3) onto the studs (12). Install the nuts (2). Do not tighten the nuts (2) at this time. Note: Exhaust elbows are only an option for the four cylinder engines.
If equipped, install the exhaust elbow onto the exhaust adapter (3). Refer to this Disassembly and Assembly Manual, "Exhaust Elbow - Remove and Install".
Illustration 3 g01038456
Tighten the three nuts finger tight in the sequence (17), (18), and (19). Tighten the nuts (17), (18), and (19) in the same sequence to a torque of 25 N m (18 lb ft).
Ensure that there is no restriction in the inlet hose. Position the air inlet hose on the turbocharger compressor housing. Install the hose clamps. Tighten the hose clamps to a torque of 5 N m (44 lb in). Note: The air inlet hose has a reflective heat shield that partially covers the hose. The reflective heat shield must be installed toward the engine. The reflective heat shield must be kept clean and free from dust, oil or paint.Note: Apply a solution of water and 5% soap to the inlet of the turbocharger in order to install a new air inlet hose. Do not use oil or grease in order to install the air inlet hose.
Position the exhaust pipe onto the exhaust elbow or onto the turbocharger outlet (3). Refer to the OEM information for the correct procedure in order to install the exhaust pipe.