31235-ZZ3-003 Honda CASE ASSY., GEAR

2. Disconnect ether tube (2) from the elbow.3. Remove the bolts and disconnect hoses (3) from the turbocharger.4. Remove the bolts and tube assembly (1) from the turbocharger and the tube assembly. 5. Remove bolts (5) and upper shield assembly (4) from the lower shield assembly. 6. Loosen four clamps (6) and move hose (7) away from the turbocharger. 7. Loosen clamp (9) and strap (8). Move pipe assembly (10) away from the turbocharger. 8. Loosen clamp (13) so compressor housing (11) can be turned and elbow (12) disconnected from the aftercooler. 9. Remove the bolts and tube (14) from the flywheel housing and the turbocharger. 10. Loosen clamps (15) to make removal of four bolts (16) easier. Remove four bolts (16) and the nuts that hold the turbocharger to the manifold. 11. Fasten tool (A) and a hoist to turbocharger (17) as shown. Remove the turbocharger and the gasket from the manifold. The weight of the turbocharger is 34 kg (75 lb.).Install Turbocharger
1. Fasten tool (A) and a hoist on turbocharger (1) as shown. Put the gasket and turbocharger (1) in position on the manifold. 2. Put 5P3931 Anti-Seize Compound on the threads of four bolts (3). Install four bolts (3) and the nuts that hold the turbocharger and the gasket to the manifold. Tighten the nuts to a torque of 55 5 N m (41 4 lb.ft.).3. Put 5P3931 Anti-Seize Compound on the threads of clamps (2). Tighten the clamps to a torque of 8 .5 N m (71 4 lb.in.). After the engine has been operated for a short period of time, tighten the bolts again to a torque of 8 .5 N m (71 4 lb.in.). 4. Install the gaskets and tube (4) on the flywheel housing and the bottom of the turbocharger. 5. Inspect O-ring seals (7) for wear or damage and make a replacement if necessary. Put clean engine oil on the O-ring seals.6. Move the compressor housing so elbow (6) can be connected into the aftercooler. Tighten clamp (5) to a torque of 14 1 N m (10 1 lb.ft.). Use a soft hammer and hit lightly all around the clamp. Tighten clamp (5) again to a torque of 14 1 N m (10 1 lb.ft.). 7. Connect pipe assembly (8) to the pipe assembly and the turbocharger. Tighten clamp (10) and strap (9). 8. Connect hose (12) to the turbocharger and tighten clamps (11). 9. Install upper shield assembly (13) on the lower shield assembly as shown. 10. Put the gasket in position and install tube assembly (14) on the turbocharger and the tube.11. Put the gasket in position and connect hoses (16) to the turbocharger.12. Connect ether tube (15) to the elbow.13. Fill the cooling system with coolant to the correct level. See the Maintenance Guide.Disassemble Turbocharger
START BY:a. remove turbocharger 1. Remove bolt (3), washer (2) and elbow (1) from the turbocharger. 2. Loosen clamp (4) and remove compressor housing (5) and the clamp from the cartridge assembly. 3. Remove bolts (6) and plate (7) from the plate. 4. Bend locks (9) away from bolt (8). Remove bolts (8), locks (9) and the cartridge assembly from turbine housing (10).
To prevent possible damage to the shaft, do not put a side force on the shaft of the wheel assembly when the compressor wheel nut is loosened.
5. Put the cartridge assembly in position on tool (A) as shown.6. Use tool (B), a universal joint and a socket to remove the nut from the wheel assembly shaft. The wheel assembly is free to fall after it is removed from the cartridge assembly.7. Use a press to remove wheel assembly shaft (11) from the cartridge assembly and wheel (12).8. Remove compressor wheel (12) from the cartridge assembly. 9. Remove ring (13) and shroud (14) from the wheel assembly. 10. Remove spacer (15) from the backplate assembly. 11. Remove rings (16) and (17) from spacer (15). 12. Bend locks (19) away from bolts (20). Remove bolts (20), locks (19) and backplate assembly (18) from the housing assembly. 13. Remove collar (21), bearing (23) and O-ring seal (22) from the housing assembly. 14. Remove bearing (24) and the washer. Use tool (C) to remove the snap ring from the compressor side of the housing assembly. 15. Use tooling (C) and remove the snap ring from the turbine side of the housing assembly. Remove bearing (26) and washer (27). Use tool (C) to remove snap ring (25) from the turbine side of the housing assembly.16. If necessary, remove the pins from the housing assembly.Assemble Turbocharger
1. Clean and inspect all parts of the turbocharger for wear or damage and make a replacement if necessary. Put clean engine oil on all parts in the housing assembly. 2. If pins (2) were removed, install them in the housing assembly 2.08 mm (.082 in.) above surface (X).3. Use tool (A) to install snap ring (1) in the turbine side of the housing assembly. 4. Install washer (4) and bearing (3) in the housing assembly. Use tool (A) to install the snap ring into the turbine side of the housing assembly. 5. Use tool (A) and install snap ring (5) into the compressor side of the housing. 6. Install washer (7) and bearing (6) into the compressor side of the housing assembly. 7. Install O-ring seal (9) on the housing assembly.8. Put bearing (10) in position on the pins in the housing assembly. Make sure the grooves in the bearing are toward the outside as shown.9. Put collar (8) in position on bearing (10). Make sure the counterbore in the collar is up. 10. Make sure oil passage (11) in the backplate assembly is in alignment with the oil passage in the housing assembly when the backplate assembly is installed on the housing assembly. 11. Install rings (13) on spacer (12). Make sure the gaps in the rings are 180° apart. 12. Put backplate assembly (16) in position on the housing