0281823 JOHNSON DECAL SET

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-6396 O-Ring Assembly
Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01335496
Typical example
Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If the turbocharger is worn, the complete turbocharger must be replaced.
Test the wastegate actuator (19) for correct operation. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect". If the wastegate actuator is damaged or the wastegate actuator does not operate within the specified limits, the wastegate actuator must be replaced. Refer to Disassembly and Assembly, "Turbocharger - Dissassemble" and refer to Disassembly and Assembly, "Turbocharger - Assemble" for more information.
Illustration 2 g01335756
Clean the mating surfaces of the exhaust manifold (1). If necessary, install studs (16) to the exhaust manifold. Tighten the studs to a torque of 18 N m (13 lb ft). Note: Support the exhaust manifold during installation of the turbocharger.
Install a new joint (15) to exhaust manifold (1).
Position turbocharger (12) on exhaust manifold (1). Note: Ensure that the turbocharger is correctly oriented.
Install nuts (11). Tighten the nuts to a torque of 44 N m (32 lb ft).
If a new turbocharger is installed, bearing housing (18) and compressor housing (20) must be oriented to the correct positions. Refer to Illustration 1. Follow Steps 7.a through 7.d in order to orient the bearing housing and the compressor housing.
Loosen band clamps (21) sufficiently in order to allow the housings to rotate. Note: If the band clamps are damaged, replace the band clamps.
Carefully turn bearing housing (18) until the port for oil feed (17) is upward.
Rotate compressor housing (20) until the compressor outlet is in the correct position. Refer to the turbocharger that was originally installed for the correct orientation.
Ensure that band clamps (21) are correctly oriented. Refer to the turbocharger that was originally installed for the correct orientation. Tighten the band clamps finger tight.
Ensure that tube assemblies (4) and (7) are clean and free from damage. Replace any damaged components.
Position a new joint (13) and bolts (14) onto tube assembly (4).
Install tube assembly (4) to turbocharger (12). Tighten bolts (14) finger tight.
Remove the plug from oil inlet port (17). Refer to Illustration 1. Lubricate the turbocharger bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor several times in order to lubricate the bearings.
Install banjo bolt (9) and new sealing washers (10) to tube assembly (7).
Use Tooling (A) in order to lubricate a new O-ring seal (6). Install O-ring seal (6) to tube assembly (7). Refer to Illustration 3.
Install tube assembly (7) to turbocharger (12). Tighten banjo bolt (9) finger tight.
Illustration 3 g01335754
Install exhaust manifold (1) and the assembly of the turbocharger to the cylinder head. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install" for the correct procedure.
Install bolt (8) finger tight. Ensure that tube assembly (7) fits correctly.
Position a new joint (3) between the flange of tube assembly (4) and the cylinder block. Install bolts (5) finger tight.
If a new turbocharger has been installed, check that the orientation of bearing housing (18) is correct. If the orientation of the bearing housing is not correct, rotate the bearing housing until tube assemblies (4) and (7) fit correctly. Tighten band clamps (21) to a torque of 13 N m (9.6 lb ft).
Tighten banjo bolt (9) to a torque of 20 N m (14 lb ft). Tighten bolt (5) and (8) to a torque of 22 N m (16 lb ft).
Install the bolts for tube clips (2) to the cylinder block. Tighten bolt (2) to a torque of 44 N m (32 lb ft).
If the turbocharger has an exhaust elbow, install the exhaust elbow. Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install".
If the turbocharger has a remote wastegate solenoid, connect the hose for the solenoid to the turbocharger.
Connect the air inlet hose and tighten the hose clamp.
Connect the air outlet hose to the turbocharger and tighten the hose clamp.