840962 Volvo.Penta Turbocharger

Illustration 1.Dimensions for Item 2.A. 23.9 mm (0.94 in)B. 54.0 mm (2.125 in)C. 34.9 mm (1.375 in)D. 10.5 mm (0.41 in)
Illustration 2.Dimensions for Item 3.E. 19.0 mm (0.75 in )F. 13.8 mm (0.54 in)G. 38.1 mm (1.50 in)
Illustration 3.Dimensions for Item 4.D. 10.5 mm (0.41 in)E. 295.0 mm (11.63 in)F. 248.0 mm (9.75 in)G. 273.0 mm (10.75 in)H. 44.5 mm (1.75 in)I. 19.0 mm (0.75 in)
Illustration 4.Dimensions for Item 5.M. 46.0 mm (1.8 in)N. 108.0 mm (4.25 in)P. 25.4 mm (1.0 in)R. 8.7 mm (0.344 in) dia., 3/8-16 UNC Thd.
Illustration 5.Dimensions for Item 7.E. 19.0 mm (0.75 in)F. 13.8 mm (0.54 in)S. 114.3 mm (4.50 in)
Illustration 6.Dimensions for fabricating the mounting bracket.U. 1143.0 mm (45.0 in)V. 733.4 mm (28.88 in)W. 63.5 mm (2.50 in)X. 50.8 mm (2.0 in)Y. 73.0 mm (2.88 in)2. Fabricate the mounting bracket to the dimensions shown in Illustration 6.
Photograph 1. Location of the bracket assembly on the machine. 3. Use two bolts (8) in order to attach the bracket assembly to the upper two aftercooler mounting holes. Assemble the bracket assembly to the air conditioner core mount using two hex head bolts (9). Refer to Photograph 1 for the location of the bracket.
Photograph 2.Fuel core assembly mounted to the bracket.4. Assemble fuel core assembly (10) to the bracket using two bolts (11), two plain washers (14), and four isolators (12). Position the core assembly with the inlet and outlet ports located by the counterweight side of the bracket and directed toward the engine. Assemble one washer and one isolator to the bolt. Assemble the bolt to the core. Assemble one isolater to the bolt between the core and the bracket. Repeat the process for the second bolt.5. Assemble fuel core assembly (10) to the bracket using two bolts (11), four isolators (12), two plain washers (14), and two full nuts (15). Assemble one washer and one isolator to the bolt. Assemble the bolt to the core. Assemble one isolater to the bolt between the core and the bracket. Secure the assembly with the nut. Repeat the process for the second bolt. Refer to Photograph 2 for the location of the core on the bracket.6. Assemble two flared reducers (16) and two flared nuts (17) to the fittings on the core.7. Remove the rear bottom engine guard and the air inlet guard below the fan compartment.8. Cut hose (18) to create two 2.44 m (8 ft) pieces. Assemble one end (19) to one piece of the hose using one hose clamp (21). Assemble one connector (20) to the opposite end of that hose using one hose clamp (21). Repeat the assembly process for the remaining piece of hose.9. Route the assembled hoses from the fuel cooler core through the lower RH corner of the radiator compartment. There is an opening where the foam baffle is located in the corner of the compartment. The hoses will pass through the fan compartment at that opening located below the alternator.
Illustration 7.Typical Fuel Lines Group.Z. Location to cut existing fuel return line in order to install the hoses that were assembled in Step 8.10. Secure the hoses to the fan motor hose with cable straps. Cut the fuel return line just below the bracket where it is clamped in the engine compartment as shown in Illustration 7. Assemble the core assembly hoses to the fuel return line using clamps (21).11. Start the engine and confirm there are no leaks.12. Replace the bottom engine guard and fan inlet guard. COPYRIGHT 1999 CATERPILLAR ALL RIGHTS RESERVED