Installing The Turbocharger (TC)

Fig 1: Identifying Correct Tool Sizes For Nuts

Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE:

When installing the studs they should always be secured with thread sealant 1161076- 5.

Install the 3 new studs on the exhaust manifold. Tighten to 30 Nm .

Clean the mating surfaces on the exhaust manifold.

Check that all dust covers are removed and that the turbine moves easily in the new turbocharger (TC)

Install the new turbocharger (TC) on the exhaust manifold with new nuts and new bi-hexagonal screws.

Lubricate the threads and mating surfaces with copper paste, P/N 1161408-8.

Tighten all screws and nuts to 60 Nm .

NOTE:

Use special wrenches to torque tighten as shown in the illustration.

Fig 2: Locating Lower Oil Return Pipe And Heat Deflector Plate Bolts

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install

the lower oil return pipe on the turbocharger (TC) with a new gasket. Tighten to 25 Nm .
the heat deflector plate. Tighten to 8 Nm .

Ensure that the mating surfaces to the cylinder head and exhaust manifold are even and clean.

Install the turbocharger (TC) with the exhaust manifold on the engine. Use the new nuts, washers and gaskets.

NOTE:

Place the metal side of the gaskets against the cylinder head.

Note the sequence. Cylinders 1-2 and 3-5 have different gaskets.

Fig 3: Identifying Exhaust Manifold Nuts

Courtesy of VOLVO CARS OF NORTH AMERICA.

Tighten the exhaust manifold to 25 Nm .