829813 Volvo.Penta Thermostat

1. Remove the bolts to disconnect pipes (1) and (2) from the shutoff housing assembly. 2. Disconnect wiring harness (3) from the shutoff solenoid. Remove the wiring harness from the grommet on the shield. 3. Fasten a hoist to shutoff housing assembly (4). Remove the bolts that hold housing (4) to the aftercooler housings. Remove shutoff housing assembly (4) from the engine. The weight of housing (4) is approximately 30 kg (65 lb).Install Air Inlet Shutoff (3516)
1. Fasten a hoist to shutoff housing assembly (1) and put it with a gasket in position on the engine. Install the bolts that hold housing (1) to the aftercooler housings. 2. Install wiring harness (2) through the grommet on the shield. Connect wiring harness (2) to the shutoff solenoid. 3. Install the bolts to connect pipes (3) and (4) to the shutoff housing assembly.Disassemble Air Inlet Shutoff (3516)
Start By:a. remove air inlet shutoff (3516) 1. Remove the bolt to remove knob (4) from the shaft assembly.2. Remove bolts (2) to remove shield (3) and cover assembly (1) from the shutoff housing assembly.3. Remove the seal from cover assembly (1). 4. Remove the bolts and remove shutoff solenoid (5) from the shutoff housing assembly.
Shaft assembly (6) has a spring force on it. To prevent possible personal injury be sure lever assembly (7) does not move when the bolts to remove plate assembly (8) are removed. If lever assembly (7) is moved, it releases the spring force that closes plate assembly (8) in the bore of the shutoff housing assembly.
5. Remove the bolts and spacers to remove plate assembly (8) from the shaft assembly. 6. Move lever assembly (7) to let shaft assembly (6) move to the closed position.7. Remove bolt (10) to remove lever assembly (7), spring (9), two washers and a sleeve from the shutoff housing assembly. 8. If necessary, remove the bushings from lever assembly (7). 9. Remove shaft assembly (6) from the shutoff housing assembly. 10. Remove dowel (13) to remove latch (11), spring (12) and washer (14) from the shaft. 11. Remove the bolts and remove cover (15) from the shutoff housing assembly. 12. If necessary, remove bushings (16) from the shutoff housing assembly.Assembly Air Inlet Shutoff (3516)
1. If necessary, install bushings (1) in the shutoff housing assembly. The bushings must be 0.35 0.15 mm (.014 .006 in) below the surface of the bore in the shutoff housing assembly. Install the cover and bolts on the shutoff housing assembly. 2. Put washer (4), spring (3) and latch (2) in position on the shaft. Make sure the short end of spring (3) is correctly engaged in the hole in latch (2). Install dowel (5) through latch (2) and the shaft to hold the assembly together. Put marks (stake) both ends of the dowel. 3. Install shaft assembly (7) in the shutoff housing assembly. Make sure the long end of spring (3) is correctly engaged in hole (6) in the shutoff housing assembly. 4. If necessary, install the bushings in lever assembly (11). The bushings must be 0.80 0.30 mm (.031 .012 in) below the surface of the lever assembly at both ends.5. Install washer (12), lever assembly (11), sleeve (10), washer (9) and bolt (8) in the shutoff housing assembly. 6. Install spring (13) between lever assembly (11) and the shutoff housing assembly.7. Turn shaft assembly (7) until lever assembly (11) and the latch on the shaft assembly are engaged as shown in the open position.
Shaft assembly (7) has a spring force on it. To prevent possible personal injury be sure lever assembly (11) does not move when the bolts to install plate assembly (14) are installed. If lever assembly (11) is moved, it releases the spring force that closes plate assembly (14) in the bore of the shutoff housing assembly.
8. Install plate assembly (14) with the bolts and spacers to hold it on the shaft assembly.9. Put plate assembly (14) in the closed position. Use a feeler gauge to check the distance between the plate and housing bore. A feeler gauge 0.8 mm (.03 in) must not go between the plate and housing bore. 10. Turn shaft assembly (7) back to the open position as shown.11. Install shutoff solenoid (15) with a gasket and the bolts to hold it in the shutoff housing assembly. Make sure the plunger from the solenoid is correctly engaged with the groove (slot) in the lever assembly. 12. Use Tooling (A) to install seal (16) in cover assembly (17). Make sure the lip of the seal is toward the inside cover (17) as shown. Also the seal must be even (flush) with the outside surface of cover (17). 13. Put cover assembly (17) and shield (18) in position and install the bolts to hold these to the shutoff housing assembly.14. Install knob (19) on the end of the shaft assembly. Make sure the long point on the knob is toward the word "Open" on the cover assembly.End By:a. install air inlet shutoff (3516)