0435728 JOHNSON ENGINE COVER ASSEMBLY, 70

Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-5597 Anti-Seize Compound 1 \
Illustration 1 g02352951
Illustration 2 g02352668
Ensure that turbocharger (8) is clean and free from damage. Inspect the turbocharger for wear. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If any part of the turbocharger is worn or damaged, the complete turbocharger must be replaced.
If bracket (24) has not been removed, loosen nuts (26). Follow Step3.d through Step 3.e in order to ensure that the bracket is correctly positioned. Note: Bracket (24) must be able to move freely to allow correct positioning.
Follow Step 3.a through Step 3.e in order to install bracket (24) to cylinder block (25).
If necessary, install studs (27) (not shown) to cylinder block (25). Tighten the studs to a torque of 18 N m (159 lb in).
Position bracket (24) onto studs (27) (not shown)
Loosely install nuts (26). Note: Bracket (24) must be able to move freely to allow correct positioning.
Apply sufficient pressure in Position (A) to ensure that bracket (24) is at the lowest point on studs (27) (not shown). Do not release the pressure on bracket (24) in Position (A) until nuts (26) have been tightened securely.
Tighten the nuts to a torque of 44 N m (33 lb ft) in the sequence shown in Illustration 2.
Illustration 3 g02352690
Illustration 4 g02352719
Position turbocharger (8) onto bracket (24). Follow Step 4.a through Step 4.c in order to locate the turbocharger in the correct position.
Loosely install nuts (28) to studs (23). Note: Turbocharger (8) must be able to move freely to allow correct positioning.
Apply sufficient pressure in Position (B) to ensure that turbocharger (8) is in the furthest position away from the cylinder block. Do not release the pressure on the turbocharger in Position (B) until nuts (28) have been tightened securely.
Tighten the nuts to a torque of 44 N m (33 lb ft) in the sequence shown in Illustration 4.
Illustration 5 g02176246
Illustration 6 g02176278
Remove plugs and caps from tube assemblies. Ensure that tube assembly (14) and tube assembly (20) are clean and free from damage. Replace any damaged components.
Install a new gasket (21) (not shown) onto tube assembly (20).
Position a new gasket (19) (not shown) onto tube assembly (20).
Remove the plug from the drain port of the turbocharger. Remove the plug from the cylinder block.
Position tube assembly (20) into the cylinder block and install bolts (22) finger tight.
Position tube assembly (20) onto turbocharger (8) and install bolts (18) finger tight.
Tighten bolts (18) and bolt (22) to a torque of 22 N m (195 lb in).
Remove the plug from oil inlet port (29) for turbocharger (8). Lubricate the turbocharger bearings with clean engine oil through oil inlet port (29). Rotate the wheel of the compressor several times in order to lubricate the bearings.
Position a new gasket (15) (not shown) onto tube assembly (14) and install bolts (13). Note: Holes in the gasket have serration that hold the bolts captive.
Position tube assembly (14) onto turbocharger (8). Tighten bolts (13) finger tight.
Remove plug from cylinder block for the oil feed tube assembly. Install new sealing washers (16) (not shown) and banjo bolt (17) to tube assembly (14). Tighten banjo bolt (17) finger tight.
Tighten bolts (13) to a torque of 22 N m (195 lb in). Tighten banjo bolt (17) to a torque of 33 N m (292 lb in). Refer to Illustration 3.
Illustration 7 g02176245
Connect hose assembly (9) onto turbocharger (8) and loosely install bolt (10).
Use Tooling (A) to lubricate the allen head bolt for V-band clamp (4). Position V-band clamp (4) onto air duct (5).
Remove plugs from the ports of the turbochargers.
Position hose assembly (12) and air duct (5) onto the outlet of turbocharger (8) and the inlet of turbocharger (3). Tighten the allen head bolt for V-band clamp to a torque of 12 N m (106 lb in). Note: Ensure that the allen head bolt for the V-band clamp does not contact any other engine component.
Tighten hose clamps (11) to a torque of 6 N m (53 lb in).
Install bolt (6) (not shown).
Tighten bolt (10) and bolt (6) (not shown) to a torque of 22 N m (195 lb in).
Use Tooling (A) to lubricate the allen head bolt for V-band clamp (2). Position V-band clamp (2) onto elbow (1).
Use Tooling (A) to lubricate the allen head bolt for V-band clamp (7). Position V-band clamp (7) onto turbocharger (8).
Position elbow (1) onto turbocharger (8) and turbocharger (3).
Tighten allen head bolt for V-band clamp (2) and V-band clamp (7) finger tight. Ensure that the V-band clamps are seated correctly onto the turbochargers.
Tighten allen head bolts for V-band clamp (2) and V-band clamp (7) to a torque of 12 N m (106 lb in).
Connect the air inlet hose to the turbocharger and tighten the hose clamp securely. End By:
Install flexible exhaust pipe.