0340786 JOHNSON COVER, Exh. hsg., front

At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gauge to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
Hot engine oil and components can cause personal injury. Do not allow hot engine oil or components to contact the skin. Be sure that the engine and components are cool enough to touch with your bare hand prior to performing any service work.
1. Drain the coolant from the engine cooling system in a suitable container for storage or disposal until the coolant level is below the turbochargers. The procedure for the removal and installation is the same for both left and right turbochargers. Removal and installation of the left side is shown.2. Put a lifting sling in position around pipe assembly (2). Attach the lifting sling to a suitable lifting device.3. Remove clamp (3). Remove four bolts (1) and the washers. Remove pipe assembly (2). 4. Remove two bolts (5) and the washers from the adapter.5. Disconnect tube assembly (4) and hose assembly (6). Cap and plug all openings to prevent coolant loss.6. Remove band clamp (8). Turbocharger compressor housing (7) must be removed from the left side turbocharger only.7. Remove turbocharger compressor housing (7). 8. Place a suitable container under drain elbow (10) to contain any oil that could be in drain elbow (10) or the turbocharger. Remove two bolts (9), and disconnect drain elbow (10). 9. Disconnect tube assembly (12). Cap and plug openings to prevent coolant loss.10. Attach lifting slings and a suitable lifting device to turbocharger (8) as shown.11. Mark and identify eight bolts (13) and (14) for installation purposes. Remove eight bolts (13) and (14) and the locknuts.12. Carefully remove turbocharger (11) from the engine. The weight of turbocharger (11) is approximately 52 kg (115 lb).13. Remove the gasket from between the exhaust flange housing and the turbocharger turbine housing. Remove the gasket from the drain elbow. The following steps are for the installation of the turbochargers. Be sure all parts are clean and the mating surfaces are smooth. Use all new gaskets and seals. 14. Put a new gasket in position on the exhaust flange housing and the drain elbow.15. Attach lifting slings and a suitable lifting device to turbocharger (11) as shown. The weight of turbocharger (11) is approximately 52 kg (115 lb).16. Put turbocharger (11) in place on the exhaust flange housing.17. Apply 5P-3931 Anti-Seize Compound to the threads and bearing surfaces of bolts (13) and (14) and the locknuts. Install bolts (13) and (14) and the locknuts. Tighten bolts (13) and (14) to a torque of 55 10 N m (40 7 lb ft)18. Connect tube assembly (12). 19. Apply 5P-3931 Anti-Seize Compound to the threads and bearing surfaces of bolts (9). Install two bolts (9) holding drain elbow (10). 20. Put the seal in position on the adapter. Put turbocharger compressor housing (7) in position and install clamp (8). Tighten the nut on clamp (8) to a torque of 14 N m (10 lb ft). Tap lightly all around clamp (8) with a soft hammer and tighten clamp (8) again to a torque of 14 N m (10 lb ft).21. Connect tube assembly (4) and oil supply hose assembly (6).22. Install two bolts (5) and the washers that connect the adapter to the aftercooler. 23. Put a lifting sling in position around pipe assembly. Put pipe assembly (2) in position as shown.24. Install clamp (3). Tighten the nut on clamp (3) to a torque of 15 3 N m (11 2 lb in). Tap lightly all around clamp (3) with a soft hammer and tighten clamp (3) again to a torque of 15 3 N m (11 2 lb ft).25. Install four bolts (1) and the washers.26. Refer to the Operation & Maintenance Manual for all fluid capacities and the proper filling procedures.End By:a. install rear hood assemblyDisassemble & Assemble Turbocharger
Start By:a. remove turbochargers
Before the start of the disassembly process, mark the housings and joints to be certain that all components are returned to their correct relative positions. The identity marks must not damage the flanges or joints, but should be sufficient to remain in evidence after the components have been cleaned.
1. Remove band clamp (1). Upon assembly, tighten band clamp (1) to a torque of 13 N m (10 lb ft). Tap lightly all around band clamp (1) with a soft hammer and tighten band clamp (1) again to a torque of 13 N m (10 lb ft).2. Remove turbocharger compressor housing (2) from the turbocharger cartridge. 3. Remove piping adapters (3) and covers (4). 4. Remove band clamp (5). Upon assembly, tighten band clamp (5) to a torque of 13 N m (10 lb ft). Tap lightly all around band clamp (5) with a soft hammer and tighten band clamp (5) again to a torque of 13 N m (10 lb ft).5. Remove exhaust adapter (6). 6. Remove eight bolts (7) and two retainers (8). Upon assembly apply 4C-5598 Anti-Seize Compound to the threads of eight bolts (7) and tighten the bolts to a torque of 41 N m (30 lb ft). 7. Lift turbocharger cartridge (10) from turbocharger turbine housing (9).
Exhaust Adapter (6). Band Clamp (5). Turbocharger Turbine Housing (9). Turbocharger Cartridge (10). Band Clamp (1). Turbocharger Compressor Housing (2).8. Turbocharger components upon disassembly. For assembly of the turbocharger, reverse the disassembly steps. Be sure all components are clean before assembly.End By:a. install turbochargers