0435238 JOHNSON ENGINE COVER ASSY.

1. Remove the hood. Remove turbocharger oil lines, water lines and heat shield. 2. Install strap and hoist then remove bolts (1), clamp and muffler. The weight of muffler is 29.5 Kg (65 lb.)3. Remove air pipe, four turbocharger bolts and remove turbocharger. The following steps are for the installation of the turbocharger.4. Inspect all gaskets and O-ring seals for damage, and make a replacement if needed.5. Put clean engine oil on O-ring seals. Position gasket and turbocharger on exhaust manifold. Put 5P3931 Anti-Seize Compound on the bolts that hold it to the exhaust manifold. Tighten the bolts to a torque of 54 5 N m (41 4 lb.ft.).6. Install air pipe.7. Install muffler and tighten clamp and bolts (1).8. Install all water and oil lines and install heat shield.9. Install hood.Disassemble Turbocharger
Start By:a. remove turbocharger 1. Install the turbocharger in tool group (A). Put alignment marks on the three housings of the turbocharger for correct installation and alignment at assembly. Remove "V" clamp (2) and compressor housing (1). 2. Remove "V" clamp (3). Remove cartridge housing (5) from turbine housing (4).
When the nut is loosened, do not put a side force on the shaft. This can result in a bent shaft.
3. Install tool (C) in tool (B), and put the cartridge assembly in tool (C) as shown. Use tool (D) to remove the nut that holds compressor wheel (6). 4. Put the cartridge assembly in tool (E), and use a press (if necessary) to remove compressor wheel (6) from the turbine wheel and shaft assembly. Do not let the turbine wheel and shaft assembly fall during removal of the compressor wheel from the turbine wheel and shaft. 5. Remove seal ring (7) and shroud (8) from turbine wheel and shaft assembly (9). 6. Bend the tabs of the locks from bolts (10), and remove the bolts and locks.7. Remove backplate assembly (11) from the cartridge housing. 8. Remove spacer (12) from backplate assembly (11). Remove seal rings (13) from spacer (12). 9. Remove collar (14), thrust bearing (15) and O-ring seal (16) from the cartridge housing. 10. Remove top bearing (17) and the washer from the cartridge housing. Put a long dye mark on the top face of bearing (17).11. Use tool (F), and remove the two rings that hold the top and bottom bearings in position. Remove the bottom bearing and washer. Put a short dye mark on the bearing. The dye marks are used for identification of the bearings when they are installed.12. Use tool (F), and remove the last ring that holds the bottom bearing in position from the cartridge housing.13. Check all the parts of the turbocharger for damage. If the parts are damaged, use new parts for replacement. See Special Instructions, Form No. SMHS6854, for Turbocharger Reconditioning. Also, see Guidelines For Reusable Parts, Form No. SEBF8018.Assemble Turbocharger
1. Make sure that all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material.2. Put clean engine oil on all parts of the cartridge assembly.
Rings (18), (21) and (22) must be installed with the round edge of the outside diameter of the rings toward the bearings.
3. Install ring (21) in the cartridge housing with tool (F).4. Install washer (19) and bearing (20) in the cartridge housing. Make sure the short dye mark on bearing (20) is up. 5. Install rings (18) and (22) in the cartridge housing with tool (F). 6. Install washer (23). 7. Install bearing (17) with the long die mark up. 8. Install bearing (15). Align the pins in the cartridge with the holes in the bearing. Be sure the three lubrication grooves are facing up as shown. 9. Install collar (14) with the small diameter toward bearing (15). Put O-ring (16) in position. Put 6V2055 High Vacuum Grease in the grooves of spacer (12) to one half or more of the depth of the grooves all the way around.10. Use tool (B), and install seal rings (13) on to spacer (12). 11. Install spacer (12) into backplate (11). Be sure the camfered end of spacer (12) is toward the inside of the cartridge assembly when the backplate assembly is installed. 12. Install backplate assembly (11) on the cartridge assembly with the oil hole in the backplate assembly in alignment with the oil hole in the cartridge housing. 13. Install locks and bolts (10) that hold backplate assembly (11) in position. Tighten the bolts to a torque of 10 1 N m (90 9 lb.in.). Put 6V2055 High Vacuum Grease in the groove for seal ring (7) at assembly to one half or more of the depth of the groove all the way around.14. Install shroud (8), and install seal ring (7) using tool (I) on turbine wheen and shaft assembly (9). 15. Position the cartridge assembly on tool (H), and install turbine wheel and shaft assembly (9) into the cartridge assembly. Make sure the seal ring on turbine wheel and shaft assembly (9) is fitted correctly in the cartridge housing. 16. Install tool (C) in tool (B), and place the cartridge assembly in tool (C). Install compressor wheel (6) on the shaft.
Do not put a side force on the shaft when the nut that holds the compressor wheel in position is tightened.
17. Put a small amount of clean engine oil on the turbine shaft threads and compressor wheel face that makes contact with the nut. Install the nut, and tighten it to a torque of 17 N m (13 lb.ft.) to push compressor wheel (6) on the shaft. Loosen the nut, and tighten it again to a torque of 3.5