0434909 JOHNSON ENGINE COVER ASSY., 140

START BY:a. remove turbocharger 1. Make an alignment mark on compressor housing (1), cartridge assembly (3) and turbine housing (4) for correct installation.2. Loosen clamp assembly (2). Remove compressor housing (1) and cartridge assembly (3) from the turbine housing. 3. Remove bolts (6) and plates (5) that hold cartridge assembly in the compressor housing. Remove cartridge assembly (3). 4. Remove O-ring seal (7) from the cartridge assembly.
To prevent a bent shaft, do not put a side force on the turbine shaft when the compressor wheel nut is loosened.
5. Put cartridge assembly (3) in position in tooling (A), and loosen the nut on the compressor wheel with tooling (C). 6. Remove nut (8) and compressor wheel (9). 7. Remove shaft and wheel assembly (10) from the cartridge assembly. 8. Remove shroud (11) from the cartridge assembly. 9. Remove four bolts (12); then remove backplate (13) from the cartridge assembly. 10. Remove spacer (14) from the backplate. 11. Remove two seal rings (15) from the spacer. 12. Remove snap ring (16) from the cartridge housing with tool (B). 13. Remove bearing (17) and the rings from the cartridge housing. 14. Remove snap ring (18) from the cartridge housing with tool (B). 15. Turn the cartridge housing over; then remove screws (20), plate (21) and collar (19). 16. Remove bearing (22) from the cartridge housing. 17. Remove snap ring (23) from the cartridge housing with tool (B).Assemble Turbocharger (AiResearch TM5101)
Make sure all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Put clean engine oil on all parts of the cartridge assembly.1. Install snap ring (1) in the cartridge housing with tool (A). Make sure the oil hole in plate (5) is open and clean to prevent a bearing failure.2. Install bearing (2), collars (3), plate (5) and screws (4). Tighten the screws to a torque of 2.5 0.2 N m (22 2 lb.in.). Install the rings that hold the bearings in position with the round outside edges of the rings toward the bearings.3. Turn the cartridge housing over. Install snap ring (6) in the cartridge housing with tool (A). Install bearing (7), ring (8) and ring (9) in the housing. Install snap ring (10) with tool (A). Put 6V2055 High Vacuum Grease in the grooves for seal rings (11). Fill the grooves to one half or more of the depth all the way around the grooves.4. Install seal rings (11) on spacer (12). 5. Install spacer (12) in the backplate. 6. Put backplate (13) in position on the cartridge housing, and install the bolts that hold it. Tighten the bolts to a torque of 9.5 1 N m (84 9 lb.in.). 7. Put shroud (14) in position on the cartridge housing. Put 6V2055 High Vacuum Grease in the groove for the oil seal ring, on the shaft and wheel assembly (15).8. Install shaft and wheel assembly (15) in the cartridge housing. 9. Put the cartridge assembly in position in tooling (B).10. Put a small amount of clean engine oil on the wheel face that will be under the nut.11. Put compressor wheel (17) in position on the shaft.
Do not put a side force on the shaft when the nut is tightened.
12. Install nut (16), and tighten it to a torque of 4 N m (35 lb.in.). Tighten the nut 120° more. 13. Put the cartridge assembly in a vise. Use tool group (C) to check end play. The end play must be 0.051 to 0.081 mm (.0020 to .0032 in.). 14. Put a small amount of clean engine oil on O-ring seal (18); then install it on the cartridge housing. 15. Put the cartridge housing on compressor housing (20), and install plates (21) and bolts (19). 16. Put turbine housing (22) in position on the cartridge housing, and install clamp (23) that holds it. Tighten the clamp to a torque of 14 1 N m (120 12 lb.in.).END BY:a. install turbocharger.