0335475 JOHNSON COVER, Stern bracket, port

1. Disconnect turbocharger oil supply line (1) and oil return line (2) from the turbocharger. 2. Loosen clamp (3) that holds the hose to the turbocharger. 3. Remove bolts (8) that hold elbow (7) in place. Remove elbow (7) and coupling (11).4. Remove bolts (6) that hold pipe (4) and flange to the aftercooler cover. Turn pipe (4) up.5. Remove bolts (10) that hold the turbocharger to the exhaust manifold. Remove turbocharger (9) and pipe (4) as a unit. Remove bolt and washer (5) and remove pipe (4) from the turbocharger.Install Turbocharger
1. Inspect all O-ring seals and gasket for damage and make replacements if needed. Put clean oil on the O-ring seals. 2. Install pipe (1) in the turbocharger. Install the washer and bolt that holds the pipe in the turbocharger.3. Put turbocharger (2) in position on the exhaust manifold. Put the gasket for the turbocharger in place. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold the turbocharger to the exhaust manifold. Install the bolts and nuts and tighten to a torque of 40 4 lb.ft. (55 5 N m). 4. Put the gasket in place and install bolts (3) that hold the pipe and flange to the aftercooler cover. Tighten the bolt that holds the pipe in the turbocharger.5. Put coupling (4) and elbow (5) in position in the turbocharger and on the exhaust manifold. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold elbow (5) in place. Install the bolts and nuts. 6. Tighten clamp (6).7. Put the gaskets in place and connect the turbocharger oil return line and oil supply line (7) to the turbocharger.end by:a) install mufflerDisassemble Turbocharger (Airesearch TV6136) (6N3678)
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. Remove "V" clamp (2) and compressor housing (1). 2. Remove "V" clamp (3). Remove the cartridge housing (5) from the turbine housing (4). 3. Put the cartridge assembly on tool (B) as shown. Use tool (D) and the correct size socket to remove the nut that holds compressor wheel (6) on the shaft.
When the nut is loosened, do not put a side force on the shaft.
The oil used to heat the compressor wheel must have a flash point (the temperature at which the oil will burn) above 400°F (204°C).
4. Install tool (H) on tool (E). Heat tool (E) to 350°F (176°C). Install the cartridge assembly on tool (H) so only the compressor wheel is in the oil. Heat the compressor wheel for no more than 10 minutes.
Do not let the turbine wheel hit the bottom of the press.
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). Step 5 must be done before the compressor wheel becomes cooler. 6. Install tool (C) in tool (B). Remove seal ring (8) and shroud (7) from the shaft. 7. Bend the tabs of the locks from bolts (9) and remove the bolts and locks. Remove the backplate assembly (10) from the cartridge housing. 8. Remove collar (11) from the backplate assembly. 9. Remove spacer (12) from the backplate assembly. Remove the seal rings from the spacer. 10. Remove ring (13) and thrust bearing (14) from the cartridge housing. 11. Remove top bearing (15) and the washer from the cartridge housing. Put a long dye mark on the top face of bearing (15). 12. Use tool (J) and remove the two rings that hold top and bottom bearings in position. Remove the bottom bearing and washer. Put a short dye mark on the bearing. The dye marks are used for identification of the bearings when they are installed.13. Use tool (J) and remove the last ring that holds the bottom bearing in position from the cartridge housing.14. Check all 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 TV6136) (6N3678)
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 edge of the rings toward the bearings.
3. Install ring (1) in the cartridge housing with tool (B).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 (4) and (5) in the cartridge housing with tool (B). 6. Install washer (7) and bearing (6) with the long dye mark up as shown. 7. Install ring (8) and thrust washer (9) with the lubrication grooves up. 8. Install seal rings (11) on spacer (10). Install spacer (10) in the backplate assembly. 9. Install collar (12) on the backplate assembly as shown. 10. Install backplate assembly (13) 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 that hold backplate assembly (13) in position. Tighten the bolts to a torque of 90 10 lb.in. (10.2 1.1 N m). 12. Install tool (D) in tool (C).13. Put 6V2055 High Vacuum Grease in the turbine end seal ring groove for seal ring (15). Make sure it fills approximately one half or more of the groove depth for the complete circumference of the groove. Install turbine shaft (14) in tool (D). Install seal ring (15) on the turbine shaft. 14. Install shroud (16) on the turbine shaft as shown. 15. Install cartridge assembly (17) on the turbine shaft as shown.