954305 Volvo.Penta Tube

1. Disconnect oil supply line (3) and oil drain line (4).2. Remove two bolts (7), and bolt (1) and the washer. Remove manifold inlet elbow (5) and outlet elbow (6) as a unit.3. Remove four bolts (8) and the four locknuts, and remove turbocharger (2). The following steps are for the installation of the turbocharger.
Before four bolts (8) and the four locknuts, which hold the turbocharger to the exhaust manifold, are tightened, all oil tubes, air pipes and exhaust pipes should be aligned and tightened without binding.
4. Check the condition of the gasket used between the turbocharger and the exhaust manifold. If the gasket is worn or damaged, use a new part for replacement. Put the gasket and turbocharger (2) in position on the exhaust manifold. Put 5P3931 Anti-Seize Compound on the threads of the bolts and the locknuts that hold the turbocharger to the exhaust manifold. Install four bolts (8) and the four locknuts, but do not tighten them at this time.5. Inspect the gasket and O-ring seals used on inlet elbow (5) and outlet elbow (6). If the gasket or the O-ring seals are worn or damaged, use new parts for replacement. Put manifold inlet elbow (5) and outlet elbow (6) as a unit in position. If alignment of outlet elbow (6) is necessary, loosen the V-band clamp only enough to allow the housing to rotate. Align outlet elbow (6) to the housing and install two bolts (7), and bolt (1) and the washer.6. Check the condition of the gaskets used on oil supply tube (3) and oil drain tube (4). If the gaskets are worn or damaged, use new parts for replacement. Connect the oil supply tube and the oil drain tube to the turbocharger.7. Tighten the V-band clamp nuts to a torque of 14 1 N m (125 9 lb in).8. Tighten four bolts (8) that hold the turbocharger to the exhaust manifold to a torque of 55 5 N m (40 4 lb ft).End By:a. install mufflerb. install air cleaner groupDisassemble Turbocharger
Start By:a. remove turbocharger1. Put identification marks on the two housings and the cartridge assembly for use at assembly. 2. Remove two clamps (3) and make a separation of compressor housing (1) and turbine housing (2) from the cartridge assembly.
When the nut is loosened, do not put a side force on the shaft.
3. Put cartridge assembly (4) in position on tooling (A). Remove the nut from the shaft. 4. Use a press to push the shaft assembly out of the cartridge assembly. Remove compressor wheel (5). 5. Remove seal ring (8) and shroud (7) from shaft assembly (6). 6. Remove snap ring (9) with tool (B). 7. Use two screwdrivers to remove insert (10) from the cartridge housing. 8. Remove O-ring seal (12) from the insert.9. Remove sleeve (11) from the insert. Remove the seal ring from the sleeve. 10. Remove deflector (13) from the housing. 11. Remove ring (14) from the cartridge housing. 12. Remove sleeve (15) and bearing (16) from the cartridge housing. 13. Remove ring (17). 14. Use tool (C) to remove snap ring (19), bearing (18) and snap ring (20) from the cartridge housing. 15. Turn the cartridge housing over. Use tool (C) to remove snap ring (22), bearing (21) and snap ring (23) from the housing.Assemble Turbocharger
1. Make sure all oil passages are open and clean. Put clean engine oil on all parts before assembly. 2. Use tool (A) to install snap ring (23), bearing (21) and snap ring (22) in the housing. Install the snap rings with the round side toward the bearing. 3. Turn the housing over. Use tool (A) to install snap ring (20), bearing (18) and snap ring (19). Install the snap rings with the round side toward the bearing. 4. Put ring (17) in position in the housing. 5. Put bearing (16) in position. Make an alignment of the holes in the bearing with the dowels in the housing. Grooved side of the bearing must be up.6. Put sleeve (15) in position in the housing. 7. Put ring (14) in position on top of the bearing. 8. Install deflector (13) as shown. 9. Put seal ring (24) in position on sleeve (11). Install the sleeve in insert (10).10. Put O-ring seal (12) in position on the insert. 11. Put insert assembly (10) in position in the housing. 12. Use tool (B) to install snap ring (9) in the housing. 13. Put shaft assembly (6) in position on tooling (C).14. Put 6V2055 High Vacuum Grease in the seal ring groove on the shaft assembly.15. Install seal ring (8) on shaft assembly (6).16. Put shroud (7) in position on the shaft assembly. 17. Put cartridge assembly (4) and compressor wheel (5) in position on the shaft assembly.
Do not put a side force on the shaft when the nut is tightened.
18. Put a small amount of oil on the face of the compressor wheel that will be under the nut. Install the nut and tighten it to a torque of 60 3 N m (44 2 lb ft).19. Remove the nut and put 9S3265 Retaining Compound on the threads of the shaft. Install the nut and tighten to a torque of 60 3 N m (44 2 lb ft).20. Put the cartridge housing assembly in position in a vise with soft jaws. 21. Put tooling (D) in position and check the end play. The end play must be between 0.08 - 0.20 mm (.003 - .008 in). 22. Put compressor housing (1) and turbine housing (2) in position and install clamps (3).23. Tighten the clamps to a torque of 14 1 N m (125 9 lb in).End By:a. install turbocharger