876209 Volvo.Penta Repair kit

1. Remove nuts (7) and dust ejector tube (2) from the muffler. Loosen clamp (6) and remove muffler (4) from elbow (8).2. Remove nuts (10). Remove elbow (8) from the turbocharger.3. Remove bolts (3). Disconnect tube (12) for oil supply from the engine block. Remove tube (12) for oil supply to the turbocharger. Remove bolts (9). Remove the bolt and the clamp that hold tube (11) for oil drain to the engine block. Remove tube (11).4. Loosen clamps (1) that hold hose (5) to the turbocharger. Loosen the clamps from the hose that connects the turbocharger to the air inlet for the cylinder head. 5. Remove the bolts and the nuts that hold the turbocharger to the exhaust manifold. Remove turbocharger (13). The following steps are for the installation of the turbocharger. 6. Put turbocharger (13) in position on the exhaust manifold and in position in the hose. Tighten clamps (1) that hold the two hoses to the turbocharger. 7. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold the turbocharger to the exhaust manifold. Install bolts (14) and the nuts. Tighten the nuts to a torque of 55 5 N m (40 4 lb.ft.).8. Put tube (12) for oil supply and tube (11) for oil drain in position on the turbocharger and install the bolts that hold them. Connect tube (12) to the engine block. Install clamp (6) and the bolt that holds tube (11) to the engine block.9. Put elbow (10) in position on the turbocharger and the exhaust manifold. Install nuts (11) that hold it.10. Put muffler (8) in position on elbow (10). Install dust ejector tube (7) on the muffler and install the nuts that hold it.11. Tighten clamp (9) that holds the muffler to the elbow.Disassemble Turbocharger
Start By:a. remove turbocharger 1. Install turbocharger on tool group (A). Put marks on the three housings of the turbocharger for correct installation and alignment at assembly.2. Remove eight bolts (1) and lockwashers. Remove four plates and compressor housing (2). 3. Remove two locks, two plates and four bolts (3) that hold the cartridge housing to the turbine housing. Remove cartridge housing (4).
When the nut is loosened, do not put a side force on the shaft.
4. Put the cartridge assembly on tool (B) as shown. Use tool (C) and the correct size socket to remove the nut that holds compressor wheel (5) on the shaft.5. Hold the cartridge assembly down in tool (B) and lift and turn the compressor wheel (5) at the same time to remove it from the shaft. 6. Remove cartridge assembly (6) from the shaft. 7. Remove bearing (7) and ring (8) from the shaft. 8. Remove ring (9) from the housing assembly with tool (D). 9. Remove the insert, sleeve and deflector from the housing assembly as a unit. Use two screwdrivers to remove the unit. 10. Remove O-ring seal (14) from insert (13). Remove sleeve (10) from the insert and deflector (11). Remove ring (12) from the sleeve. 11. Remove bearing (15) from the housing assembly. 12. Turn the housing assembly over. Remove shroud (16) and the gasket from the housing assembly.Assemble Turbocharger
1. Make sure that all of the oil passages in the cartridge housing assembly are clean and free of dirt and foreign material. Put clean oil on all the parts of the cartridge assembly.2. Put shaft (17) in position in tool (A). Install ring (8) and bearing (7) in the shaft as shown. 3. Put shroud (16) in position on the shaft as shown. 4. Put gasket (18) in position on the shroud. Install housing assembly (4) over the shaft. 5. Install bearing (15) in the housing assembly. Make sure the bronze side of the bearing is up. 6. Put deflector (11) in position over sleeve (10).7. Install ring (12) in the groove on the sleeve. Push the sleeve into insert (13). Install O-ring seal (14) on the insert. 8. Install the insert, deflector and sleeve as a unit in the housing assembly as shown. 9. Install ring (9) in the groove in the housing assembly with tool (B). 10. Put compressor wheel (5) in position on the shaft.
Do not put a side force on the shaft when the nut that holds the compressor wheel in position is tightened.
11. Install the nut that holds the compressor wheel in position. Tighten the nut to a torque of 18.7 1.7 N m (165 15 lb.in.). 12. Put turbine housing (19) in position on tool (C). Put cartridge assembly (4) in position in the housing. Make sure the mark on the cartridge assembly is in alignment with the mark on the housing. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold cartridge assembly to the turbine housing. Install the two locks, two plates and four bolts that hold the cartridge assembly to the turbine housing. Tighten the bolts to a torque of 15 to 17 N m (11 to 12 lb.ft.). Bend the locks over the bolts. 13. Put compressor housing (2) in position on the cartridge assembly. Make sure the mark on the housing is in alignment with mark on the cartridge assembly. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold the compressor housing to the cartridge assembly. Install the four plates and eight bolts and lockwashers that hold the compressor housing in position. Tighten the eight bolts to a torque of 6.8 N m (60 lb.in.).End By:a. install turbocharger