L.-J~~~~~!!:-.-J
Subject:
Parts
Bulletin
Grp
2C-No.
27
December
1986
IlATBR-COOLED
TtJRBOCBARGER
821FT
(v/o
CARS
intercooler)
B21FTL
(vi
intercooler)
UP
TO
1985
Group
25
Date:
FEBRUARY
1987
Page l of
6
THIS
BULLETIN
APPLIES
TO
THE
U.S.
AND
CANADA,
AND
SUPERSEDES
25-47
DATED
DECEMBER
1986.
No.
41
REFERENCE:
SERVICE
MANUAL
TP
30163/2
{English),
ENGINES
B17,819,821,823
X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
Installation
of a vater-cooled
turbocharger
NaTE: The
designation
B21FTL
is
used
to
denote
a B21FT
engine
equipped
with
either
a
factory-installed
intercooler
or
a
dealer-installed
intercooler
kit.
If
it
is
necessary
to
replace
a
turbocharger,
a new
water-cooled
unit
·
should
be
installed.
It
may
also
be
necessary
to
replace
the
exhaust
manifold,
expansion
tank
and
support
braeket.
• The
early
type
of
exhaust
manifold
(up
to
81-1/2)
has a flat
flange
which
will
not
fit
to
the
new
water-cooled
turbocharger.
It
is,
therefore,
necessary
to
use
a new
exhaust
manifoid.
• The
flat
type
of
expansion
tank
should
be
replaced
by
the
new
cylindrical
type.
. .
•
1983
and
earlier
vehicles
with
the
early-type
turbocharger
ring
support
braeket
do
not
require
the
new
lower
support
braeket
but,
if
desired,
it
may
be
installed
according
to
the
Repairs
and
Maintenance
Service
Manual
TP
30163/2
Section
2
(25-29)
page
41,
operation
PI-PlI.
1984
and
1985
vehicles
have
the
lower .support
bracket
which
should
be
reinstalled
upon
assembly.
•
Two
installation
kits
are
available
as
follows:
Early
type
(up
to
81-1/2)
••••...•••••..••••••.
P/N
270602-6
Late
type
(from
81-1/2
on)
••••••••••••••••••••
P/N
270198-5
Turbocharger
Engine
B21FTL
(=
intercooler)
821FT
P/H
5003632-6
(exch)
5003631-8
(exch)
Important
that
all Service Personnel Read - Circulate and
initial
SERVICE
SHOP
SERVICE
SERVICE
TECHNICIANS
MANAGER
FOREMAN
WRITER
I
I
I
1 l
I I
-
© VOLVO NORTH
AMERICA
CORPORATION
Prlnted
In
the
U.S.A.
I I
SPECIAL TOOLS:
Pressure
Gauge
....................................
P/N
999
5230-1
P/N
998
6408-4
Sealing
Tool
..................
G
•••••••••••••••••••
Early
type
(up
to
81-1/2)
Installation
kit
P/H
210602-6
Part
P/N
Part
P/H
4
Washers
11996-6
2
Lock
plates
1326222-5
1
Washer
419401-5
2
Lock
plates
1326586-3
1
Gasket
420423-6
1
Exhaust
manifold
1336237-1
1
Gasket
420475-6
1
Pin
Stud
1336261-1
4
Gaskets
463846-6
1
Bracket
1336265-2
2
Bolts
940132-4
1
Leaf
spring
1336266-0
2
Bolts
941686-8
1
Bracket
1336683-6
4
Hose
clamps
943471-3
1
Expansion
Tank
1336684-4
1
Hose
clamp
943472-1
1
Water
hose
1336973-1
1
Hose
clamp
943476-2
1
T-connector
1378420-2
8
Lock
nuts
946036-1
1
Water
hose
1378421-0
1
Bolt
946440-5
1
T-connector
1378548-0
2
Lock
nuts
948645-7
1
Water
pipe
1378551-4
2
Spacers
1257499-2
1
Water
pipe
1378621-5
1
Sealing
ring
1306264-1
1
Water
hose
1378624-9
Additional
parts:
3
Studs
P/N
1357769-7
Late
type
(from
81-1/2)
Installation
kit
P/H
210198-5
Part
P/N
Part
P/H
4
Washers
11996-6
2
Lock
plates
1326222-5
l
Gasket
420423-6
2
Lock
plates
1326586-3
1
Gasket
420475-6
1
T-connector
1378420-2
4
Gaskets
463846-6
1
Water
hose
1378421-0
2
Bolts
941686-8
1
T-connector
1378548-0
4
Hose
clarnps
943471-3
1
Water
pipe
1378551-4
2
Hose
clarnps
943476-2
1
Water
pipe
1378621-5
1
Sealing
ring
1306264-1
1
Water
hose
1378624-9
Additional
Parts:
3
Studs
.......................
P/N
1357769-7
8
Lock
nuts
...................
P/N
946036-1
3
Hose
clarnps
.................
P/N
943472-1
l
Hose
clamp
..•..•••••........
P/N
943473-9
Page
2
of
6
P20
SB
25-47;
FEBRUARY
1987
Page 3 of
6
If
the
car
has
a
flat
type
of
expansion
tank,
the
following
parts
are
also
needed
1
Bracket
................•...
.
.....•.....
P/N
1336683-6
1
Expansion
tank
................•.......
P/N
1336684-4
1
Water
hose
.................•..........
P/N
1336973-1
tU
~l
Turn
to
page
30
of
Service
Manual,
Repairs
and
Maintenance
Section
2
(25-29)
ReIDove
turbo
charger
(See
operations
NI-N7.)
Following
are
additional
to
steps
in
Manual:
N1
Disconnect
-probe
NS
Remove
oil
return
pipe
If
the
exhaust
manifold
has
P/N
1336237-1
(late
typei
see
Service
Manual
pg.
29,
step
L5),
then
the
turbocharger
should
be
separated
from
the
manifold.
Drain
Coolant
Move
dashboard
heater
control
to
max
heat.
Unscrew
expansion
tank
cap.
Unscrew
drain
cock
on
right-hand
side
of
cylinder
block.
Disconnect
hose
from
bottom
of
radiator.
Carry
out
operations
H23-H27
(Service
Manual)
There
is
an
error
in
the
Service
Manual
for
operation
N23:
The
word
not
should
be
deleted.
Connect
the
lower
water
pipe
to
the
turbocharger.
Carry
out
operations
N28-N31
Following
are
additional
to
steps
in
Manual:
N31
Connect
oil
return
pipe
-
lower
support
braeket
(only
required
for
1984/85
vehicles)
-
lower
heat
plate
Install
3 new
studs
at
the
exhaust
side
of
the
turbocharger.
Connect
the
upper
vater
pipe
3ke
sure
the
water' pipe
is
not
too
near
the
oil
pres~
e
pipe.
If
the
car
has
a
flat
type
of
expansion
tank,
it
must
be
replaced
by
a new
cylindrica
-l
type.
Remove:
-
flat
expansion
tank,
bracket
and
water
hose
Fit:
_ .
- new
expansion
tank
(cylindrical)
- new
bracket
- new
water
hose
Page 4 of
6
P20
SB
25-47;
FEBRUARY
1987
-'
Pag
Fit
upper
T-connector
Cut
expansion
tank
hose
as
follows~
B21
FT
,.
65mrn
from
expansion
tank
B21
FTL
75mrn
from
expansion
tank
Remove
ISmm
from
lower
hose.
Loosely
secure
T-connector
using
two
hose
clamps.
Fit
lover
T-connector
Cut
lower
radiator
hose
95mm from
center
of
hose
(see
left).
Remove
15
..
from.
lower
hose.
Loosely
secure
T-connector
using
two
hose
clarnps.
Connect
short
hose
Connect
the
short
hose
to
the
turbo-
charger
lower
water
pipe
and
the
T-connector
(in
lower
radiator
hose)
.
Tighten
hose
clamps.
Connect
long
hose
Connect
the
long
hose
to
the
tu~bc
charger
upper
water
pipe
and
the
T-connector
(in
expansion
tank
h:se)
·
Tighten
hose
clarnps.
Carry
out
operations
H32-H36
(Service
Manual)
Connect
the
-probe.
Labor
op.
255122
Fill
with
coolant
Tighten
drain
cock.
Fill
expansion
tank
to
max.
Warm
up
engine,
making
sure
that
dashboard
heater
control
is
set
to
max
heat.
Check
for
leakage
and
top-
up
if
required.
Check
charge
pressure;
see
checking/adjusting
on
page
16.
Carry
out
operations
F1-F9.
Description
Water-cooled
turbocharger,
install
Page 6 of
6
Time
allowance
4.1
hrs.
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