5030639 JOHNSON CUSHION, Flywheel cover

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more information. If the turbocharger is worn, the complete turbocharger must be replaced.
Test the turbocharger actuator for correct operation. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more information. If the actuator is damaged or the actuator does not operate within the specified limits, the complete turbocharger must be replaced.
Illustration 1 g02862040
If necessary, follow Step 3.a through Step 3.f in order to install boost pressure chamber cover (29).
Position gasket (23) (not shown) onto boost pressure chamber cover (29).
Position boost pressure chamber cover onto the engine oil cooler and install bolts (26). Tighten the bolts to a torque of 10 N m (89 lb in)
Install a new sealing washer (28) to banjo bolt (27). Install the banjo bolt assembly to hose assembly (22) and install the remaining sealing washer (28). Install hose assembly (22) to boost pressure chamber cover (29) finger tight.
Install tube assembly (22) into clip (21).
Install a new sealing washer (25) to banjo bolt (24). Install the banjo bolt assembly to hose assembly (6) and install the remaining sealing washer (24). Install hose assembly (6) to boost pressure chamber cover (29) finger tight.
Install the alternator and mounting bracket. Refer to Disassembly and Assembly, "Alternator - Remove and Install" for the correct procedure.
Illustration 2 g02862480
Clean the gasket surfaces of exhaust manifold (19). If necessary, install studs (17) to exhaust manifold (19) and turbocharger (11). Tighten the studs to a torque of 15 N m (133 lb in).
Position a new gasket (20) (not shown) onto turbocharger (11).
Position turbocharger (11) onto exhaust manifold (19) and install washers (16) and new nuts (15). Tighten the nuts to a torque of 28 N m (248 lb in). Note: Do not use the actuator rod to lift the turbocharger.
Illustration 3 g02859585
Illustration 4 g02859796
If necessary install new O-ring seals (8) onto tube assembly (9). Install tube assembly (9) into the cylinder block.
Position a new gasket (7) (not shown) onto tube assembly (9).
Position tube assembly (9) onto the turbocharger. Install bolts (10) to tube assembly (9). Tighten the bolts to a torque of 10 N m (89 lb in).
Lubricate the bearings of the turbocharger with clean engine oil through the oil inlet port. Rotate the shaft of the turbocharger in order to distribute the lubricant.
If necessary, install a new sealing washer (13) onto connection (14). Install connection assembly (14) to the cylinder block. Tighten the connection assembly to a torque of 22 N m (195 lb in).
Position tube assembly (12) onto connection assembly (14). Loosely install nut (15).
Position a new sealing washer (1) (not shown) onto banjo bolt (2). Install banjo bolt (2) onto tube assembly (12) and install remaining new sealing washer (1) to banjo bolt (2). Tighten the banjo bolt to torque of 22 N m (195 lb in).
Tighten nut (15) to torque of 22 N m (195 lb in).
Connect hose assembly (6) to the wastegate actuator. Tighten the hose clamp securely.
Connect hose assembly (4) to the turbocharger. Tighten the hose clamp securely.
Illustration 5 g02862956
Tighten banjo bolt (28) to a torque of 12 N m (106 lb in). Note: Ensure that the hose assembly does not come into contact with any other engine components.
Tighten banjo bolt (24) to a torque of 12 N m (106 lb in). Note: Ensure that the hose assembly does not come into contact with any other engine components.
Connect the hose assemblies to the turbocharger inlet and the turbocharger outlet. Tighten the hose clamps securely.
Install the flexible exhaust pipe to the turbocharger. Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure.