1546487 Volvo.Penta Valve spring washer

start by:a) remove turbocharger 1. Install turbocharger in tool group (A). Remove "V" clamp (2) and compressor housing (1). 2. Remove "V" clamp (3). Remove the cartridge housing (5) from the turbine housing (4). 3. Put the cartridge housing in tool (B). Use a T-handle (6) and remove the nut that holds compressor wheel (7). Remove the compressor wheel.
When the nut is loosened, do not put a side force on the shaft.
4. Remove the cartridge housing from tool (B). Remove the turbine wheel (9) and shaft from the cartridge housing. Remove seal ring (8) from the shaft. 5. Remove the snap ring that holds insert (10) in the cartridge housing. Remove the insert with tooling (C). 6. Remove the sleeve (13) from the insert (11). Remove the two seal rings (12) from the insert. 7. Remove deflector (14), ring (16), sleeve (15), bearing (18) and ring (17) from the cartridge housing. If the oil hole is not open this will cause a bearing failure. 8. Remove the snap ring that holds bearing (19) in the cartridge housing. Remove bearing (19). Remove snap ring (20) with tool (D). 9. Remove the snap ring that holds bearing (21) in place with tool (D). Remove bearing (21) and sleeve (22) from the cartridge housing. 10. Turn the cartridge housing over. Remove snap ring (23). Remove shroud (24). 11. Remove snap ring (25) from the cartridge housing with tool (D).12. Inspect all parts and install new parts as needed.Assemble Turbocharger (Schwitzer F522)
1. Make sure all oil passages are open and clean. Put engine oil on all parts before assembly. 2. Install snap ring (1) in the cartridge housing with tool (A). Install the snap rings with the round side toward the bearing. 3. Install shroud (4) on the housing. Turn the shroud to make sure it is down on the housing even. The high part (2) on the housing will keep the shroud in position on the housing after assembly.4. Install the snap ring (3). 5. Turn the cartridge housing over. Install sleeve (6) and bearing (5). Install the snap ring that holds bearing (6) in the cartridge housing with tool (A). 6. Install snap ring (8) with tool (A). Install bearing (7). Install the snap ring that holds bearing (7) in place. Install the snap rings with the round side toward the bearing. 7. Install ring (12), bearing (13), sleeve (10), ring (11) and deflector (9) in the housing.
The oil hole in bearing (13) must be open and clean.
8. Install seal rings (15) in sleeve (16). Install the sleeve in insert (14). 9. Check O-ring seal (17). Make a replacement of the seal if necessary. Install insert (18) in the cartridge housing (19). Install the snap ring to hold the insert in place. The flat side of the snap ring must be toward the insert. Put 6V2055 High Vacuum Grease in the groove for seal ring (20) at assembly to one half or more of the depth of the groove all the way around.10. Put clean engine oil on shaft (21). Install seal ring (20) on the shaft. Install the shaft in the cartridge housing. 11. Put cartridge housing in tool (B). Put 6V1541 Primer on the threads of the shaft and the nut that holds the compressor wheel to the shaft. Install compressor wheel (22) on the shaft. Put 9S3265 Retaining Compound on the nut and the threads of the shaft.
Do not let the 9S3265 Retaining Compound get into the compressor wheel bore. It will make disassembly of the compressor wheel difficult in the future. Do not put a side force on the shaft when the nut is tightened.
12. Put a small amount of lubricant on the area of the nut that makes contact with the compressor wheel. Install the nut that holds the compressor wheel to the shaft. Tighten the nut to a torque of 22 2 lb. ft. (28 3 N m).13. Install turbine housing in tool group (C). Install cartridge housing in turbine housing. Install the "V" clamp that holds the cartridge housing to the turbine housing. Put 5P3931 Anti-Seize Compound on the threads of the "V" clamp. 14. Check O-ring seal (24). Make a replacement of the seal if necessary. Install the compressor housing to the cartridge housing. Install the "V" clamp that holds the compressor housing to the cartridge housing.15. Install turbocharger in tool group (D). Loosen the "V" clamp nuts. Turn housings until they are in alignment. The oil drain hole on the cartridge housing and the exhaust opening on the turbine housing must be parallel to the tool base. The air outlet opening on the compressor housing must be at an angle of 117° from a vertical line. Tighten the "V" clamp nuts to a torque of 120 10 lb.in. (13.6 1.1 N m).end by:a) install turbocharger