16041-ZZ5-003 Honda COVER

2. Loosen the bolts that hold clamps (2) in place. Move the muffler toward the rear far enough to get clearance between the muffler and sleeve (3). 3. Remove tube assemblies (4) and (5) from the turbocharger and the engine. 4. Loosen clamps (6) and remove bolts (7). 5. Remove bolts and nuts (9) that hold the turbocharger in place.6. Remove turbocharger (8) and the sleeve from the machine. 7. Loosen clamp (10) and remove the elbow from the turbocharger.Install Turbocharger
1. Put the elbow and hose (1) in position and tighten the clamp. 2. Put sleeve (2) and turbocharger (3) in position. Install the bolts and nuts that hold the turbocharger to the exhaust manifold. Put 5P3931 Anti-Seize Compound on the threads of the bolts. 3. Install bolts (5) and clamps (4). 4. Install tube assemblies (6) and (7) on the turbocharger and the engine. Make sure the gaskets are in place. 5. Move muffler (8) toward the front of the machine into position on the sleeve.6. Tighten clamps (9) that hold the muffler in place. 7. Put tube (10) in place and connect it to the muffler and the precleaner.Disassemble Turbocharger
start by:a) remove turbocharger 1. Install turbocharger on tool group (A). Put marks on the three housings of the turbocharger for correct installation and alignment at assembly.2. Loosen clamp (2) and remove housing (1) and clamp (3). 3. Loosen clamp (3) and remove housing (4) and clamp (3). 4. Put cartridge assembly (5) in position on tooling (B).
Do not put a side force on the shaft when the nut is loosened.
5. Use tooling (C) to remove the nut from the shaft.6. Use a press to push the shaft assembly out of the cartridge assembly. 7. Remove wheel (6) from the cartridge. 8. Remove shroud (8) and the seal ring from shaft assembly (7). 9. Use tooling (D) to remove snap ring (9) from the cartridge. 10. Use screwdrivers (11) to lift up on insert assembly (10). 11. Remove sleeve (12) from the insert.12. Remove the two seal rings from the sleeve.13. Remove O-ring seal (13) from the insert. 14. Remove deflector (14) from the cartridge. 15. Remove spacer (15) from the cartridge. 16. Remove bearing (16) from the cartridge. 17. Remove sleeve (17) and O-ring (18). 18. Use tooling (E) to remove snap ring (19) from the cartridge. 19. Remove bearing (20) and the other snap ring.20. Turn the cartridge housing over. 21. Use tooling (E) to remove snap ring (21) from the cartridge.22. Remove the bearing and snap ring.Assemble Turbocharger
1. Make sure that all of the oil passages in the cartridge housing assembly are clean and free of dirt and foreign material. Put clean oil on all the parts of the cartridge assembly. 2. Install snap ring (1) in cartridge housing (2) with tooling (A).3. Install the bearing and the other snap ring.4. Turn the housing over. 5. Install snap ring (3) with tooling (A).6. Install the bearing and other snap ring. 7. Put ring (4) and sleeve (5) in position in the cartridge. 8. Install bearing (7) with the grooved side up. Make an alignment of the dowels in the housing with the holes in the bearing.9. Put spacer (6) in position on the bearing. 10. Put deflector (8) in position as shown. 11. Put seal rings (9) in position on sleeve (10).12. Install the sleeve in insert (11).13. Install O-ring seal (12) on the insert. 14. Put insert assembly (13) in position in the cartridge. 15. Use tooling (C) to install snap ring (14) in the cartridge housing. Put 6V2055 High Vacuum Grease in the groove for the seal ring at assembly to one half or more of the depth of the groove all the way around the shaft. 16. Install the seal ring on shaft assembly (16).17. Put the shaft assembly in position on tooling (B).18. Put shroud (15) in position on the shaft. 19. Put cartridge assembly (17) in position on the shaft assembly. 20. Put compressor wheel (18) in position on the shaft.21. Put clean oil on the threads on the shaft and the top surface of the wheel that makes contact with the nut.
Do not put a side force on the shaft when the nut that holds the compressor wheel in position is tightened.
22. Install the nut that holds the compressor wheel in place. Tighten the nut to a torque of 25 1 N m (20 1 lb.ft.). 23. Put the cartridge assembly in position in a vise as shown. Make sure soft jaws are used. Install tooling (E) on the cartridge assembly to check the end play. End play must be 0.114 0.038 mm (.0045 .0015 in.). 24. Put housing (20) in position on tooling (D). 25. Put cartridge assembly (19) in position in housing (20) and install clamp (22). Tighten the clamp to a torque of 13.6 N m (120 lb.in.).26. Install housing (21) on the cartridge and install clamp (23). Tighten the clamp to a torque of 13.6 N m (120 lb.in.).