823428 Volvo.Penta Pulley

Table 1
Required Tools
Tool Part Number Part Description Qty
A 5P-3931 Anti-Seize Compound -
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. Clean the mating surfaces of the exhaust manifold and the turbocharger. Clean the mating surfaces of turbocharger and the oil supply tube assembly and the oil drain tube assembly.
Ensure that the turbocharger inlet and outlet ports are clean and free from restrictions. The turbocharger shaft must rotate freely.
Illustration 1 g00975609
If necessary, install the studs (14) in the exhaust manifold. Install gasket (9) over the studs. Note: Do not use any sealant on the gasket.
Position the turbocharger (7) on the exhaust manifold.
Apply Tooling (A) to the threads of studs (14). Install the nuts (15). Tighten the nuts to a torque of 47 N m (35 lb ft).
Lubricate the bearing housing with clean engine oil.
Inspect the oil hose assemblies (12 and 18). If necessary, replace the hose assemblies. Note: The top flange of the oil drain tube assembly (18) is secured to the turbocharger with 6 mm setscrews (17). The bottom flange of the oil drain tube assembly (18) is secured to the cylinder block with 8 mm setscrews.
Position a new gasket (16) and the oil drain tube assembly (18) on the bottom of the turbocharger. Install the setscrews (17). Tighten the setscrews to a torque of 9 N m (80 lb in).
If necessary, install a new gasket and the oil drain tube assembly (18) to the cylinder block. Tighten the setscrews to a torque of 22 N m (16 lb ft).
Position new washers (11) and the oil supply tube assembly (12) on the turbocharger. Install the banjo bolt (10). Tighten the banjo bolt to a torque of 22 N m (16 lb ft). Note: Ensure that the oil supply tube assembly (12) does not come into contact with any other component when the assembly is installed onto the engine.
If necessary, install new washers and the oil supply tube assembly (12) to the cylinder block. Tighten the banjo bolt to a torque of 22 N m (16 lb ft).
If necessary, install the studs (8) in the turbocharger housing.
Illustration 2 g00975635
Position the exhaust adapter (1) on the studs (8). Install the nuts (2). Do not tighten the nuts at this time. Note: The exhaust elbow is an option for this engine.
If equipped, install the exhaust elbow (3) onto the exhaust adapter (1). Position the bracket (4) on the cylinder block and install the setscrews (6).
Install the setscrews (5) in order to secure the exhaust elbow (3) to the bracket (4).
Tighten the three nuts (2) finger tight. Tighten the nuts 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 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: Use a solution of water and 5 % soap to install a new air inlet hose. Do not use oil or grease.
Position the exhaust pipe on the exhaust elbow or onto the exhaust adapter (1). Refer to the OEM information for the correct procedure in order to install the exhaust pipe.