0435506 EVINRUDE GEARCASE ASSY., Complete

START BY:a. remove turbocharger 1. Install the turbocharger in tool group (A). Put alignment marks on the three housings of the turbocharger for correct installation and alignment at assembly. Remove "V" clamp (2) and compressor housing (1). 2. Remove "V" clamp (3). Remove cartridge housing (5) from turbine housing (4).
When the nut that holds the compressor wheel is loosened, do not put a side force on the shaft.
3. Install tool (C) in tool (B) and put the cartridge assembly in tool (C) as shown. Use tool (D) to remove the nut that holds compressor wheel (6).
The compressor wheel can often be removed from the cartridge assembly without the use of the oil cooker. The oil cooker can be used for easier disassembly. If removal of the compressor wheel is too difficult, damage to parts can be the result.
The oil used to heat the compressor wheel must have a flash point (the temperature at which the oil will burn) above 204°C (400°F).
4. Install tool (H) on tool (E). Heat tool (E) to a temperature of 176°C 14°C (350°F 25°F). Install the cartridge assembly on tool (H) so only the compressor wheel is in the oil. Heat the compressor wheel for no more than ten minutes.
Do not let the turbine wheel hit the bottom of the press during removal. Step 5 must be done before the compressor wheel becomes cooler.
5. Install tool (H) on tool (G). Put the cartridge assembly in tool (H) as shown. Remove compressor wheel (6) with an arbor press and tool (F). 6. Put the turbine wheel in tool (C). Remove seal ring (8) and shroud (7) from the shaft.7. Use tool (J) to make sure the turbocharger shaft is straight. See Special Instruction, Form No. SMHS6998. 8. Bend the tabs of the locks from bolts (10), and remove the bolts and locks.9. Remove backplate assembly (11) from the cartridge housing. Remove spacer (9) from backplate assembly (11). Remove the seal rings from spacer (9). 10. Remove the collar from behind backplate assembly (11).11. Remove thrust bearing (13) and O-ring seal (12) from the cartridge housing. 12. Remove top bearing (14) and the washer from the cartridge housing. Put a long dye mark on the top face of bearing (14). The dye marks are used for identification of the bearings when they are installed.13. Use tool (J) and remove the two rings that hold the top and bottom bearings in position. Remove the bottom bearing and washer. Put a short dye mark on the bearing. 14. Use tool (K), and remove the last ring that holds the bottom bearing in position from the cartridge housing.15. Check all the parts of the turbocharger for damage. If the parts have damage, use new parts for replacement. See Special Instruction, Form No. SMHS6854, for Turbocharger Reconditioning. Also see Guideline For Reusable Parts, Form No. SEBF8018.Assemble Turbocharger (AiResearch TW61)
1. Make sure that all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material.2. Put clean engine oil on all parts of the cartridge assembly.
Rings (1), (4) and (5) must be installed with the round outside edge of the rings toward the bearings.
3. Install ring (4) in the cartridge housing with tool (A).4. Install washer (3) and bearing (2) in the cartridge housing. Make sure the short dye mark on bearing (2) is up.5. Install rings (1) and (5) in the cartridge housing with tool (A).
Put 6V2055 High Vacuum Grease in the groove for seal ring (7) at assembly to one half or more of the depth of the groove all the way around.
6. Install tool (D) in tool (C). Install turbine shaft (6) in tool (D). Install seal ring (7) and shroud (8) on turbine shaft (6).
Make sure the seal ring on turbine shaft (6) is fitted correctly in the cartridge housing.
7. Install turbine shaft (6) in the cartridge housing. 8. Install washer (12), bearing (11) with the long dye mark up, thrust washer (10) with the three lubrication grooves up and O-ring seal (9) in the cartridge housing. 9. Install the seal rings on spacer (13). Install spacer (13) in backplate assembly (15). Make sure the chamfer end of spacer (13) is toward the inside of the cartridge assembly when the backplate assembly is installed.10. Install collar (14) and backplate assembly (15) on the cartridge assembly with the oil hole in the backplate assembly in alignment with the oil hole in the cartridge housing. 11. Install the locks and bolts (16) that hold backplate assembly (15) in position. Tighten the bolts to a torque of 10.2 1.1 N m (90 10 lb.in.).
Do not put a side force on the shaft when the nut is installed.
12. Use the following steps for the compressor wheel installation:a. Install the compressor wheel on the shaft by hand.b. Measure the distance between the compressor wheel and the backplate at the point where the compressor wheel no longer moves freely on the shaft.c. If the distance between the compressor wheel and backplate is more than 7.87 mm (.310 in.), use tool (B) and do steps d through i.d. Heat the compressor wheel to 176 14°C (350° 25&d