0390022 JOHNSON CARBASSY.,Lower

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g03459117
Loosen the hose clamp. Disconnect the hose assembly from air outlet (11) from turbocharger (3).
Slide clip (5) along hose assembly (6) (not shown). Disconnect hose assembly (6) (not shown) from the wastegate actuator.
Slide clip (13) along hose assembly (14). Disconnect hose assembly (14) (not shown) from turbocharger (3).
Remove bolt (7) (not shown) from the clip for the tube assembly.
Loosen the allen head bolt on V-band clamp (2) and V-band clamp (8) from elbow (1). Remove the V-band clamps from the elbow.Note: If V-band clamp (2) and V-band clamp (8) remain tight on the flanges, apply releasing fluid on the V-band clamps. Lightly tap the bolts on the V-band clamps with a soft faced hammer to assist removal. Do not use a prybar to remove V-band clamps.
Remove elbow (1) from turbocharger (3) and the turbocharger.Note: Plug the open ports of the turbochargers.
Loosen allen head bolt on V-band clamp (4) for air duct (12).
Loosen hose clamp (9).
Remove hose assembly (10), V-band clamp (4), and air duct (12) as an assembly from the outlet of turbocharger (4) and the turbocharger.Note: Plug the open ports of the turbochargers.
Illustration 2 g03459118
Remove banjo bolt (15) from tube assembly (16) for the oil feed for turbocharger (3).Note: Plug the port for the oil feed in the turbocharger and plug the tube assembly.
Remove sealing washers (17).
Remove bolts (19) from tube assembly (20).
Disconnect tube assembly (20) from turbocharger (3) and remove gasket (18) (not shown).Note: Plug the drain tube assembly for the turbocharger. Plug the port on the turbocharger.
Illustration 3 g03459119
Remove nuts (22) from turbocharger (3).Note: Ensure that the weight of the turbocharger is supported as the nuts are removed.
Remove turbocharger (3) from exhaust manifold (21).
Remove gasket (23).
If necessary, remove studs (24) from turbocharger (3).Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
B 4C-5597 Anti-Seize Compound 1
C 370-4653 Counterweight Tool 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 4 g03459376
Ensure that turbocharger (3) is clean and free from damage. Inspect the turbocharger for wear. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If any part of the turbocharger is worn or damaged, the complete turbocharger must be replaced.
Test wastegate actuator (25) for correct operation. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect". If any part of the wastegate actuator is worn or damaged, the complete turbocharger must be replaced.
Illustration 5 g03459363
Clean the gasket surface of exhaust manifold (21). If necessary, install studs (24) to turbocharger (3). Tighten the studs to a torque of 18 N m (160 lb in).
Install a new gasket (23) to studs (24).
Position turbocharger (3) onto the exhaust manifold and loosely install nuts (22).Note: Ensure that the turbocharger is correctly oriented.
Illustration 6 g03459362
Illustration 7 g03459359
Turbocharger tightening sequence viewed from the exhaust manifold.
If tooling (C) is not available, follow instructions in Step 6.a to align turbocharger. If tooling (C) is available, follow instructions in Step 6.b to align turbocharger (3).
Apply sufficient pressure in Position