0436997 JOHNSON COVER AY., Air silencer

1. Remove three bolts (3) used to fasten elbow to intake manifold. Remove elbow (2) and coupling (1). 2. Remove clip (6). Remove two bolts (4), tube assembly (5) and gasket from turbocharger. 3. Loosen hose clamps (7) on two hoses.4. Remove four bolts (9) and turbocharger (8) and gasket from engine.Install Turbocharger
1. Put a new gasket (3) in position on the exhaust manifold.2. Put 5P3931 Anti-Seize Compound on the threads of the four bolts that hold the turbocharger to the exhaust manifold.3. Put the turbocharger (2) in position on the exhaust manifold and install the four bolts that hold it in place. Tighten the nuts to a torque of 40 4 lb.ft. (54 5 N m).4. Install hoses on turbocharger and tighten hose clamps (1). 5. Install a new gasket and connect tube assemblies (4) and (5) to the turbocharger. 6. Install clip (8) on the tube assemblies.7. Inspect the rings on the coupling and make a replacement if necessary.8. Install coupling (6) and elbow (7) on the turbocharger. Install three bolts to hold elbow in position.Disassemble Turbocharger
start by:a) remove turbocharger 1. Put the turbocharger in position on tooling (A).2. Bend the tabs on the locks away from the bolts.3. Remove bolts (2), locks (1) and compressor housing (3). 4. Bend the tabs on the locks away from the bolts. Remove bolts (5), the locks and cartridge assembly (4) from exhaust housing (6). 5. Put the cartridge assembly in position on tooling (B).
Do not put a bending force on the shaft and wheel assembly when the nut is loosened.
6. Remove nut (7) from the shaft. 7. Push the shaft assembly (9) out of the cartridge assembly. 8. Remove wheel (8) from the cartridge.9. Remove seal ring (11) from the shaft assembly.10. Remove shroud (10) from the shaft.11. Bend the tabs on the locks away from the bolts. 12. Remove bolts (13) and locks (12).13. Remove the cartridge from backplate assembly (14). 14. Remove bearing (15) and collar (16) as a unit from the backplate assembly. 15. Remove bearing (15) from collar (16). 16. Remove seal ring (17) from collar (16). 17. Remove spring (18) from the backplate assembly. 18. Remove seal ring (19) from the cartridge housing. 19. Remove snap ring (21), bearing (20) and snap ring (22) from the cartridge housing. 20. Turn the cartridge housing over and remove snap ring (24), bearing (23) and snap ring (25).Assemble Turbocharger
1. Clean all parts thoroughly before they are assembled. Put clean engine oil on all parts. 2. Install snap ring (2), bearing (3) and snap ring (1) in the cartridge housing. 3. Turn the cartridge housing over and install snap ring (5), bearing (6) and snap ring (4). 4. Put seal ring (7) in position on the cartridge housing. 5. Put seal ring (8) in position on collar (9). 6. Put bearing (10) in position on the collar. Bearing (10) must be installed on the collar with grooved side up as shown. 7. Put bearing (10) and the collar in position on the cartridge housing as a unit. Make an alignment of the holes in the bearing with dowels (11). 8. Put spring (12) in position in backplate (13). 9. Put shaft assembly (14) in position on tooling (A).10. Fill the groove in the shaft with 6V2055 High Vacuum Grease.11. Put seal ring (16) in position on th shaft assembly.12. Install shroud (15) as shown.13. Put the cartridge housing in position on shaft assembly (14). 14. Install the backplate, locks (18) and bolts (17). Tighten the bolts to a torque of 75-90 lb.in. (8.5-10.2 N m).15. Bend the tabs on locks (18) up against the bolts. 16. Put compressor wheel (19) in position and install the nut.
Do not put a bending force on the shaft and wheel assembly when the nut is tightened.
17. Tighten the nut to a torque of 20 lb.in. (2.3 N m) plus 100°. 18. Put cartridge assembly (20) in a vise as shown. Make sure soft (brass) jaws are used.19. Install tooling (C) on the cartridge assembly to check end play. The end play must be .001 - .004 in. (0.03 - 0.10 mm). 20. Put turbine housing (21) in position on the tool (B).21. Put cartridge assembly (20) in position in the turbine housing. 22. Put 5P3931 Anti-Seize Compound on bolts (23).23. Put locks (22) in position and install the bolts. Tighten the bolts to a torque of 115 15 lb.in. (13 1.7 N m). Bend the tabs on the locks against the bolts. 24. Put compressor housing (24) in position.25. Put locks (25) in position and install bolts (26). Tighten the bolts to a torque of 115 15 lb.in. (13 1.7 N m). Bend the tabs on the locks against the bolts. end by:a) install turbocharger