243231 Volvo.Penta Relay

Table 1
Specifications for 356-1138 Turbocharger Gp    
Callout     Part Number     Part Name     Specification Description    
1     -     Bolt     Torque to...................
22 N m (16 lb ft)    
6     -     Bolt     Torque to...................
40 N m (30 lb ft)    
9     6I-0846     Bolt     Torque to...................
9 N m (80 lb in)    
13     6I-0217     Bolt     Torque to...................
22 N m (16 lb ft)    
16     147-5553     Stud     Torque to...................
18 N m (13 lb ft)    
17     6I-0563     Nut     Torque to...................
44 N m (32 lb ft)    
20     -     Actuator     The test pressure for the wastegate actuator is .
100 kPa (14.5 psi)
The test pressure for the wastegate actuator is .
1 mm (0.0394 inch)    Removal Procedure
Start By:
Remove the exhaust elbow from the turbocharger. Refer to Disassembly and Assembly, "Exhaust Elbow" for the correct procedure.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g02530062
Loosen hose clamps and disconnect the hose assemblies from turbocharger inlet (4) and from turbocharger outlet (3) .
Remove banjo bolt (1) from tube assembly (5). Remove sealing washers (2) (not shown).
Remove banjo bolt (6) from tube assembly (5). Remove sealing washers (7) (not shown).
Remove tube assembly (5) from the turbocharger and the cylinder block.
Slide hose clamp (10) along hose assembly (11). Disconnect hose assembly (6) from the wastegate actuator.
Remove bolts (13) and bolts (9). Remove tube assembly (14) from the turbocharger.
Remove gasket (8) (not shown) and gasket (12) (not shown).
Illustration 2 g02530138
Remove nuts (17). Remove turbocharger (19) from exhaust manifold (15) .Note: Do not use the actuator rod to lift the turbocharger.
Remove gasket (18) (not shown).
If necessary, remove the studs (16) (not shown) from turbocharger (19) .Installation Procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more information. If the turbocharger is worn, the complete turbocharger must be replaced.
Illustration 3 g02567758
Test actuator (20) for correct operation. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more information. If the actuator is damaged or the actuator does not operate within the specified limits, the complete turbocharger must be replaced.
Illustration 4 g02530138
Clean the gasket surfaces of exhaust manifold (15). If necessary, install studs (16) (not shown) to turbocharger (19). Tighten the studs to a torque of 18 N m (13 lb ft).
Install a new gasket (18) (not shown) to the exhaust manifold.
Position turbocharger (19) onto exhaust manifold (15) and install nuts (17). Tighten the nuts to a torque of 44 N m (32 lb ft).Note: Do not use the actuator rod to lift the turbocharger.
Illustration 5 g02530062
Position a new gasket (8) (not shown) and a new gasket (12) (not shown) onto tube assembly (14) .
Install tube assembly (14) onto the turbocharger and the cylinder block.
Install bolts (9) and bolts (13) finger tight.
Tighte