0435707 JOHNSON CRANKSHAFT ASSY.

1. Drain the coolant from the radiator until the level is below the turbochargers.2. Remove cover (1) and outer filter from the air cleaning housing. 3. Remove nuts (2) and remove inner filter (3). 4. Remove air cleaner housing (4). 5. Remove strap (5). Disconnect tube (6). Remove bolts (8), remove base and tube (7) as a unit. 6. Remove shields (9) from the turbocharger. 7. Remove clamp (10) and pipe (11). Remove adapter assembly (12). 8. Put identification on the lines and tubes for proper installation.9. Remove lines and tubes (13), (14), (15) and (16) from the turbocharger and engine. 10. Fasten straps and a hoist to the turbocharger. Remove bolt (19). Remove bolts (18) to remove turbocharger (17). Weight is 25 Kg (55 lb.). For installation of the turbocharger, reverse the procedures of Steps 1 through 10. In Step 10, put 5P3931 Anti-Seize Compound on the threads of bolts (18) and tighten bolts to a torque of 54 5 N m (40 4 lb. ft.). In Step 7 tighten clamp (10) to a torque of 14.0 1.5 N m (10 1 lb. ft.).End By: a. install hoodDisassemble Turbocharger
Start By: a. remove turbocharger 1. Put the turbocharger in position on tool group (A) as shown.2. Put marks on the housings of the turbocharger for correct installation and alignment at assembly.3. Loosen clamp (2) and remove compressor housing (3) and clamp (2) from the cartridge assembly. 4. Loosen clamp (4) and remove cartridge assembly (5) from turbine housing (6).
To prevent a bent shaft, do not put a side force on the turbine shaft when the compressor wheel nut is loosened.
5. Put the end of the turbine shaft in tooling (B). Use a universal joint and socket of the correct size to remove the nut that holds compressor wheel (7) on the turbine shaft. 6. Use a press and push the turbine shaft out of compressor wheel (7) and the cartridge housing. Remove compressor wheel (7) from the cartridge housing. 7. Remove shroud (9) from turbine shaft (8). 8. Remove seal ring (10) from turbine shaft (8). 9. Bend the tabs of the locks from bolts (11) and remove the bolts.10. Remove backplate assembly (12) from the cartridge housing. Make a note of the position of the oil holes in the backplate assembly and cartridge housing for correct alignment at assembly. 11. Push spacer (13) out of the bore in backplate (12). 12. Remove seal rings (14) from spacer (13). 13. Remove seal (15) from the cartridge housing. 14. Remove thrust collar (16) from the cartridge housing. 15. Remove thrust bearing (17) from the cartridge housing. If the bearings are to be used again, put identification on them, as to their location, for correct assembly.16. Remove bearing (18) from the cartridge housing. 17. Remove washer (19) from the cartridge housing. 18. Remove snap rings (20) and (21) with tooling (C). 19. Remove bearing (22) from the cartridge housing. 20. Remove washer (23) from the cartridge housing. 21. Remove snap ring (24) from the cartridge housing with tooling (C). 22. Turn the cartridge housing over. Remove plates (25) from the cartridge housing.Assemble Turbocharger
1. Make sure all of the oil passages in the turbocharger cartridge housing, backplate assembly and bearings are clean and free of dirt and foreign material.2. Put clean engine oil on all parts of the cartridge at assembly. 3. Install plates (1) on the cartridge housing. Turn the cartridge housing over. Make sure the round edge on the outside diameter of the snap ring is toward the bearing when the snap rings are installed.4. Install snap ring (2) in the turbine end of the cartridge housing with tool (A). Install washer (4) and bearing (3). 5. Install snap ring (5) in the cartridge housing with tool (A) to hold the washer and bearing in place. 6. Install snap ring (6) in the cartridge housing with tool (A).7. Install washer (8) and bearing (7) in the cartridge housing until washer (8) makes contact with snap ring (6). 8. Install thrust bearing (9) over the dowels in the cartridge housing. Make sure the grooves in bearing (9) are toward the outside as shown. 9. Put thrust collar (10) in position on the thrust bearing with the counterbore for the spacer up. 10. Install seal ring (11) in the groove of the cartridge housing. 11. Install seal rings (12) on spacer (13) so the gaps in the seal rings are 180° apart. 12. Install spacer (13) in backplate assembly (14). 13. Make sure the oil passage in the cartridge housing and the oil passage in the backplate assembly are in alignment. Put backplate assembly (14) in position on the cartridge housing. Make sure the spacer fits correctly in the counterbore of the thrust collar.14. Install the locks and bolts to hold backplate assembly (14) to the cartridge housing. Tighten the bolts to a torque of 10 1 N m (7 1 lb.ft.) and bend the tabs of the locks on the bolts. 15. Put turbine shaft (15) in position in tool (B). Put 6V2055 High Vacuum Grease in the groove for seal ring (16). 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 seal ring (16) on turbine shaft (15). 16. Install shroud (17) on turbine shaft (15). 17. Install the cartridge housing on the turbine shaft while the spacer in the backplate is held in position. Make sure the seal ring on the turbine shaft is fitted correctly in the cartridge housing. 18. Put compressor wheel (18) in position on the turbine shaft.