Volvo B21FT User manual

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.