0382669 EVINRUDE LEAD ASSEMBLY, Spark plug to distributor ( #2 )

1. Inspect O-ring seals (1) on the elbow. Install new seals if needed. Put clean engine oil on the O-ring seals. 2. Put the turbocharger in position on the exhaust manifold. Make sure the compressor wheel housing engages with elbow (2).3. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold the turbocharger to the exhaust manifold. Install the bolts and nuts.4. Connect the oil drain line tube to the turbocharger.5. Install the oil supply line.Disassemble Turbocharger
start by:a) remove turbocharger 1. Put the turbocharger in position on tool (A). Move tool (A) so the compressor housing is up. 2. For installation alignment purposes, make a mark on the center housing and turbine housing. Bend down the lock plates and remove six bolts (1). If some of the bolts are hard to remove, put penetrating oil on the bolt and hit the flat of the bolt head with a punch and hammer. 3. Lift the center housing and turbine wheel out of the turbine housing. If the assembly is hard to get apart, lift up on the compressor housing and hit the turbine housing with a soft hammer. 4. Remove clamp (2) from the compressor housing. For installation alignment purposes, make a mark on the center housing and the compressor housing. 5. Lift the center housing out of the compressor housing. Put the turbine wheel in tooling (B).6. Remove nut (3) with a universal socket. Remove O-ring (4).
Do not put a side force on the shaft when the nut is removed.
7. Heat the compressor wheel in oil for no more than ten minutes. The temperature of the oil must be 350° 25°F (176° 14°C).
The bearing heating oil used to heat the compressor wheel must have a flash point above 400°F (204°C).
8. Immediately after removing the compressor wheel from the oil, put the center housing in a press and use tooling (C) and (D) to remove the compressor wheel and center housing from the shaft.
Do not let the turbine wheel hit the bottom of the press.
9. Put the turbine wheel in tooling (B) and remove ring (6) and shroud (5). 10. Remove three bolts (7) and the three lock plates from center housing (8). 11. Remove plate (9) with tool (E). Remove the O-ring from plate (9). 12. Remove spacer (10) from plate (9). Remove collar (11) and thrust bearing (15). Remove bearing (12) and put a long dye mark on the top face of the bearing. Use tool (F) to remove rings (16) and (13). Remove bearing (17) and put a short dye mark on the top face of the bearing. Remove ring (14) with tool (F). The dye marks are for identification when installing the bearings.13. Inspect all parts and install new parts if needed. Use Special Instruction Form No. GMG00153-01, Turbocharger Reconditioning, Form No. FEG45138, Analyzing Turbocharger Failure and Video Tape JEG08054 (1/2 inch reel) (JEG09052-cassette), Turbocharger Reconditioning I (AIRESEARCH) for references.Assemble Turbocharger
1. Make sure all oil passages are open and clean. Put clean engine oil on all parts before assembly. 2. Install ring (3) with tool (A). Install bearing (4) with the short dye mark up. Install rings (2) and (1) with tool (A). Rings (1), (2) and (3) must be installed with the round edge toward the bearing. 3. Install shroud (5) on the turbine shaft. Install ring (6). Put 6V2055 High Vacuum Grease on ring (6) and fill the groove for the ring to one half depth all the way around the circumference. 4. Install the center housing on the turbine shaft. Make sure ring (6) on the turbine shaft fits inside the center housing correctly. Check to see the turbine shaft and center housing do not come apart. 5. Install bearing (9) with the long dye mark up. Install thrust bearing (12) with the three lubrication grooves up. Install collar (8). Install O-ring (11) around plate (10). Install plate (10). Make sure the oil hole in plate (10) is in alignment with the oil hole in the center housing. Install spacer (7) with the large bore toward the inside. 6. Install bolts (13) with the three locks. Tighten bolts (13) to a torque of 35 4 lb. in. (4.0 0.5 N m).7. Heat the compressor wheel in oil for no more than ten minutes. The temperature of the oil must be 350° 25°F (176 14°C).
The bearing heating oil used to heat the compressor wheel must have a flash point above 400°F (204°C).
8. Immediately after the compressor wheel is removed from the oil, put the wheel on the turbine shaft. Put the nut on the shaft with a universal socket and tighten the nut to a torque of 120 lb.in. (13.6 N m).
Do not put a side force on the shaft when the nut is removed.
9. When the compressor wheel has a temperature of less than 150°F (65.5°C), remove the nut. Check the face of the nut and the front face of the compressor wheel to make sure they are smooth and clean. Put lubricant on the nut and on the front face of the compressor wheel. Put 9S3265 Retaining Compound on the retaining nut if it is on a Schwitzer Turbocharger. Install the nut and tighten the nut to a torque of 30 lb. in. (3.4 N m). Put a mark across the nut and the compressor wheel. Tighten the nut 120° from the marks on the nut and compressor.10. Put solvent on the compressor wheel to remove the bearing heating oil. 11. Put the center housing in a vise. Make a measurement of the shaft end play with tool (C). See the Specifications for tolerances. If the shaft end play is not in tolerance, the parts inside the center housing must be checked for too much wear. 12. Install O-ring seal (14) around the center housing. Assemble the center housing and the compressor housing. Make sure the punch marks are in alignment.