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
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© VOLVO NORTH AMERICA CORPORATION
Prlnted In the U.S.A.
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Volvo B21FT Specifications

General

Brand	Volvo
Model	B21FT
Category	Automobile Parts
Language	English

Summary

Installation of Water-Cooled Turbocharger

Installation Kit Information

Details on available installation kits for different vehicle types.

Special Tools Required

Installation Kit Parts

Early Type Installation Kit (Up to 81-1/2)

Parts list for the early type installation kit (P/N 270602-6).

Late Type Installation Kit (From 81-1/2)

Parts list for the late type installation kit (P/N 270198-5).

Turbocharger Removal and Installation Steps

Expansion Tank Replacement Parts

Additional parts needed if the car has a flat type expansion tank.

Turbocharger Removal Procedure

Steps to remove the turbocharger, referencing the service manual.

Coolant Drainage

Instructions for draining engine coolant before removal.

Turbocharger Reinstallation

Lower Water Pipe Connection

Connecting the lower water pipe to the turbocharger.

Additional Installation Steps

Connecting oil return pipe, support bracket, and heat plate.

Upper Water Pipe Connection

Connecting the upper water pipe to the turbocharger.

Expansion Tank Replacement

Replacing the flat expansion tank with a new cylindrical type.

Hose and T-Connector Installation

Upper T-Connector Fitment

Cutting and securing the expansion tank hose for the upper T-connector.

Lower T-Connector Fitment

Cutting and securing the lower radiator hose for the lower T-connector.

Short Hose Connection

Connecting the short hose to the turbocharger and T-connector.

Long Hose Connection

Connecting the long hose to the turbocharger and T-connector.

Final Checks and Coolant Fill

Coolant Filling Procedure

Filling the expansion tank and warming up the engine.

Charge Pressure Check

Checking and adjusting charge pressure as per service manual.

Labor Operation Details

Details for labor operation 255122: Water-cooled turbocharger, install.