Volvo Penta 3863191 Mode D'emploi page 5

Purpose
Installation of exhaust riser gaskets on 1993 - 2015 iron
exhaust V6 and V8 engines.
Parts Included, 3863191
qty P/N
2 *
1 7749161
* not sold separately
Tools and Chemicals Needed
Standard socket set
Sandpaper, 80 grit
Sanding block
Straight edge
Depth micrometer
Spray on gasket remover
Workshop manual for the engine being serviced
Torque wrench
Sealant, copper-based, heat resistant gasket
compound such as;
Permatex Copper Spray-a-Gasket® (80697)
K&W Copper Coat® (401612)
NOTICE! These instructions contain detailed steps for
surface preparation, gasket installation and
torque that are necessary for proper sealing
of the gaskets. If these steps are not
followed, leakage at the gasket may occur.
This information replaces any instructions found in
earlier manuals or kit instructions.
Disassembly
See the engine workshop manual for the steps to
remove the exhaust risers and associated parts.
Note the position of all parts mounted to the riser for
later re-assembly.
Gasket surface preparation
This section only applies to the installation of new
gaskets on used exhaust manifolds and risers.
NOTICE! Clean threads in the mounting holes are
critical for torquing of the riser bolts and the
seal between the riser and manifold.
1. Check all riser mounting holes in manifolds for
debris or excessive coating on threads.
Bolts should screw completely in to hole by hand
(image 1), if not, run tap in holes to clear debris
and coating. Use shop vacuum to remove debris
from holes.
VPA 7749161 04-2015
Description
Gasket, riser
Instructions
NOTICE! Gasket surfaces will be sanded in the
following steps, take precautions to prevent
debris from entering the engine.
CAUTION! Follow precautions on gasket
remover to prevent injury and
damage to parts.
2. Use spray on gasket remover to remove ALL
traces of riser gasket from the gasket surfaces.
Do not scrape gasket off surfaces, heavy
scrapping with tools may gouge gasket surface,
preventing proper seal.
NOTICE! Do not use rotary power sanding tools, they
may leave a circular gouge in the surface.
3. Use 80 grit sandpaper and a sanding block, or
equivalent to smooth the gasket mounting surfaces
on the riser and manifold (image 2).
4. Remove all paint, coatings, gasket material, rust
and anything else that will create high or low spots
on the surface.
5. Each area/section of gasket mounting surface (see
example in image 3) should be flat and smooth to a
tolerance of 0.1mm.
6. If the surface can not be cleaned or sanded to this
tolerance, the part must be machined flat at the
gasket mounting surface.
If machined, the following applies;
• The maximum material that can be removed is
0.25mm (0.0098 in.)
• Machine flatness over the gasket surface is
0.075mm (0.0029 in.) maximum overall, with not
more than 0.02mm (0.000787 in.) allowable over
any 25mm (0.98 in.) span.
• Surface finish should not exceed 0.0032mm
(0.0001259 in.) Roughness Average
7. If the surface can not be machined to these
specifications the part must be replaced.
Assembly
1. Before installing the riser gasket, coat the mating
surfaces of both the manifold and the riser with a
copper-based, heat resistant gasket compound
(image 4).
2. Install the riser gasket (image 5).
3. Install the riser and other parts according to the
instructions or workshop manual.
4. Apply the gasket compound to the exposed edges
of the riser gasket (image 6).
5. Torque bolts in a crossing pattern to 34-39 Nm
(25-29 ft lbs) (image 7). Make at least two passes
to insure proper torque is reached .
3