840408 Volvo.Penta Push rod

1. Drain the coolant from the cooling system into a suitable container for storage or disposal.2. Remove the necessary hood covers to provide top access to the turbochargers.3. Loosen the clamps that hold tube assemblies (1) and (2) and the elbows to the turbochargers and air cleaners. Remove the tube assemblies and elbows as a unit. 4. Loosen the clamps that hold elbows (3) and (4) and the tube assemblies to the turbochargers and air cleaners. Remove the elbows and the tube assemblies as a unit. 5. Loosen the clamps that hold exhaust elbows (5) and (6) and the tube assemblies to the exhaust elbows and the muffler assemblies. Remove the tube assemblies. 6. Remove bolts (7) and the washers and remove two shield assemblies (8). 7. Remove turbocharger oil supply line (9) from each turbocharger.8. Disconnect tube assemblies (10) from the turbochargers. Remove the tube assemblies from the engine. 9. Disconnect water lines (11) from the bottom of each turbocharger. 10. Disconnect oil drain lines (12) from each turbocharger. 11. Remove the bolts that hold the outlet adapter elbows (13) to the aftercooler.12. Fasten a hoist to turbocharger (14). Remove the bolts that hold the turbocharger to the exhaust manifold, and remove the turbocharger and elbow (13) as an assembly. The weight of the turbocharger and elbows is approximately 27.7 Kg (61 lb).13. If necessary, remove elbow (13) from the turbocharger. The following steps are for the installation of the turbochargers.14. If elbows (13) were removed from the turbocharger, make sure that the O-rings seals are in place on the elbows. Apply clean engine oil on the O-ring seals and install the elbows on the turbocharger.15. Place new gaskets in position on the exhaust manifold and the aftercooler housing.16. Place turbocharger (14) and the elbow in position on the engine.17. Apply 5P-3931 Anti-Seize Compoundon the threads of the bolts that secure the turbocharger and tighten the bolts.18. Install the bolts that secure elbows (13) to the aftercooler housing.19. Place the gaskets and water lines (11) in position on the bottom of each turbocharger. Apply 5P-3931 Anti-Seize Compoundon the threads of the bolts. Install the bolts that secure the water lines in place on the turbocharger.20. Place the gaskets and oil drain lines (12) in position on the turbochargers. Apply 5P-3931 Anti-Seize Compoundon the threads of the bolts. Install the bolts that secure the oil drain lines in place.21. Apply 5P-3931 Anti-Seize Compoundon the threads of the bolts that secure the oil supply lines (9) in place. Place the gaskets and oil supply lines (9) in position on the turbochargers. Install the bolts that secure the oil supply lines in place.22. Install tube assemblies (10) to the turbochargers.23. Install the tube assemblies and elbows (5) and (6) to the exhaust elbows and the muffler assemblies. Tighten the clamps that secure the tube assemblies and the elbows.24. Install the tube assemblies and elbows (3) and (4) to the turbochargers and air cleaners. Tighten the clamps that secure the tube assemblies and the elbows.25. Install tube assemblies (1) and (2) and the elbows as a unit. Tighten the clamps that secure the tube assemblies and the elbows to the turbochargers and air cleaners.26. Using bolts (7) and the washers, install two shield assemblies (8).27. Fill the cooling system with coolant to the correct level. Refer to the Operation & Maintenance Manual for the correct capacity and fluid.