0584415 JOHNSON COVER, Powerpack to flywheel

2. Loosen two hose clamps (3) and slide hose (4) over the adapter. Remove pipe (1), adapter (2) and elbow (5). 3. Remove muffler brace (6), elbow (7) and the pipe (not shown). 4. Remove four bolts (8). Remove oil lines (9) and (10) and the gaskets. 5. Remove four bolts (13). Remove turbocharger (11) and coupling (12).Install Turbocharger
1. Check all seals and gaskets for damage. If damaged, use new parts for replacement. Install coupling (2). Put turbocharger (1) in position.2. Put 5P3931 Anti-Seize Compound on threads and install four bolts that hold the turbocharger to the manifold. Tighten the bolts to a torque of 40 4 lb.ft. (55 5 N m). 3. Install two oil lines and gaskets (3). 4. Install the pipe (not shown), elbow (5) and muffler brace (4). 5. Install elbow (9), pipe (6) and adapter (7). Slide hose (8) over the flange and tighten the hose clamps.6. Close the hoods.Disassemble Turbocharger
start by: a) remove turbocharger Put marks on turbocharger sections for correct alignment on assembly. 1. Put turbocharger (1) in position on tool (A). Loosen clamp (3) and remove compressor housing (2). 2. Loosen clamp (4). Remove cartridge assembly (5) from turbine housing (6). 3. Put the cartridge assembly in position on tool (B). Use correct size socket holder.
When nut is removed, do not put a side force on the shaft.
If the compressor wheel can not be removed easily, use a press to remove it.4. Remove the nut with tool (C) and a universal socket. Remove compressor wheel (7). 5. Remove housing (8) from the shaft. 6. Remove heat shroud (9) from the shaft. 7. Remove ring (11) from the shaft of wheel assembly (10). 8. Remove snap ring (12) from the housing. Use tool (E). 9. Remove insert (13) from the housing. 10. Push sleeve (14) from the insert with fingers. Remove the seal ring from the sleeve.11. Remove O-ring seal (15) from the insert. 12. Remove deflector (16). Remove two rings, sleeve and bearing (not shown) from the housing. 13. Remove snap ring (17), bearing (18) and the inner snap ring. Use tool (D) to remove the snap rings. 14. Turn the housing as shown. Remove snap ring (20), bearing (19) and the inner snap ring. Use tool (D) to remove the snap ring.Assemble Turbocharger
1. Make sure all oil passages are open and all parts are clean and free of dirt and foreign material. Put engine oil on all parts before assembly. Install snap rings with round edge toward the bearing. Use tool (A). 2. Install snap ring (1), bearing (2) and snap ring (3) in exhaust end of housing (7). 3. Turn the housing as shown. Install snap ring (4), bearing (5) and snap ring (6).
Put holes in bearing and deflector in alignment with dowels in housing.
4. Install ring (12), bearing (11), sleeve (10), ring (9) and deflector (8) in the housing. 5. Install O-ring seal (13) on insert (14). Install ring (15) on sleeve (16).6. Install the sleeve in the insert. 7. Install insert (14) in the housing. 8. Install snap ring (17) with tool (B). 9. Put wheel assembly (19) in position in tool (C). Put 6V2055 High Vacuum Grease in the ring groove. Make sure the grease fills the groove approximately one half or more of the groove depth for the complete circumference of the groove to help make a carbon dam under the seal ring. Install ring (18) on the shaft of the wheel assembly. 10. Install shroud (20) on the wheel assembly.11. Put the cartridge housing in position on the wheel assembly. Make sure the ring on the wheel assembly is fitted correctly in the housing.
Use a universal socket with a torque wrench. Do not put a side force on the shaft when the nut is tightened.
12. Install compressor wheel (21) on the wheel assembly. Put clean engine oil on the threads of the wheel assembly. Install the nut that holds the compressor wheel to the wheel assembly. Tighten the nut to a torque of 44 2 lb.ft. (60 3 N m). Remove nut and make an application of 9S3265 Retaining Compound to clean shaft threads. Make a replacement of the nut and tighten nut to above specifications. 13. Put cartridge housing in a vise as shown. Check the shaft end play with tool (D). The end play must be .0045 .0015 in. (0.114 0.038 mm). If the shaft end play is not correct, check Specifications for too much wear. 14. Install turbine housing (22) on tool (E). Put the cartridge housing in position in the turbine housing. Make sure the marks are in alignment on the housing. Install the "V" clamp and tighten the bolt to a torque of 120 10 lb.in. (13.6 1.1 N m). 15. Put compressor housing (23) in position on the cartridge housing. Make sure the marks on the housings are in alignment. Install the "V" clamp that holds the compressor housing to the cartridge housing. Tighten the bolt to a torque of 120 10 lb.in. (13.6 1.1 N m).end by:a) install turbocharger