0338274 JOHNSON GASKET, Muffler

1. Drain the level of coolant in the radiator below the level of the turbocharger.2. Remove the nuts and bolts that hold support assembly (1) to the lower support. Pull elbow (2) and support assembly (1) out of the turbocharger and remove them as a unit from the machine. 3. Disconnect coolant line (4) and coolant line (5) at the turbocharger. Put covers over the coolant openings.4. Remove the turbocharger oil supply line (3). 5. Remove turbocharger heat shield (6). 6. Loosen clamp (7) and remove elbow (8). 7. Fasten a hoist to turbocharger (10) with tool (A). Remove bolts (9) and lift turbocharger (10) off oil drain line (11) and pipe (12). The weight of the turbocharger (10) is 25 kg (55 lb.).Install Turbocharger
1. Install O-ring seals on line (1) and pipe (2).2. Put a thin layer of clean engine oil in the bores in the turbocharger for O-ring seals on line (1) and pipe (2).3. Fasten a hoist to turbocharger (3) with tool (A). Put turbocharger (3) in position on line (1) and pipe (2).4. Put the gasket in position on the exhaust manifold.5. Put 5P3931 Anti-Seize Compound on the threads of the bolts. Install the bolts and nuts to hold the turbine housing of the turbocharger to the exhaust manifold. Tighten the bolts and nuts to a torque of 55 5 N m (41 4 lb.ft.). 6. Put 5P3931 Anti-Seize Compound on the threads of clamp (4).7. Put elbow (5) in position and tighten clamp (4) to a torque of 8.0 0.5 N m (6 0.5 lb.ft.). 8. Install turbocharger heat shield (6). 9. Install turbocharger oil supply line (7).10. Connect coolant lines (8) and (9).11. Install the O-ring seals on the elbow for air cleaner housing support (10). 12. Put a thin layer of clean engine oil in the turbocharger opening.13. Install the elbow and support (10) on the engine.14. Fill the cooling system with coolant to the correct level.End By: a. install air cleaner housingb. install hood and mufflerDisassemble Turbocharger
Start By: a. remove turbocharger 1. Put the turbocharger in position on tool group (A) as shown. Put marks on the three housings of the turbocharger for correct installation and alignment at assembly.2. Put marks on the clamps for correct installation and alignment at assembly. Loosen clamp (2) and remove compressor housing (1) and clamp from the cartridge assembly. 3. Remove heat shield (6) from the cartridge housing. Loosen clamp (3) and remove cartridge assembly (5) from turbine housing (4). 4. Put the end of the turbine shaft in tooling (B). Use a universal joint and socket of the correct size to remove the nut that holds compressor wheel (7) on the turbine shaft.
To prevent a bent shaft, do not put a side force on the turbine shaft when the compressor wheel nut is loosened.
5. Use a press to push the turbine shaft out of compressor wheel (7) and the cartridge housing. Remove compressor wheel (7) from the cartridge housing. 6. Remove shroud (9) from turbine shaft (8). 7. Remove seal ring (10) from turbine shaft (8). 8. Bend the tabs of the locks from bolts (11) and remove the bolts.9. Remove backplate assembly (12) from the cartridge housing. Make a note of the position of the oil holes in the backplate assembly and cartridge housing for correct alignment at assembly. 10. Push spapcer (13) out of its bore in backplate (12).11. Remove seal rings (14) from spacer (13). 12. Remove O-ring seal (15).13. Remove thrust collar (16) from the cartridge housing. 14. Remove thrust bearing (17) from the cartridge housing. 15. Remove bearing (18) and the washer from the cartridge housing. If the bearings are to be used again, put identification on them as to their location for correct assembly. 16. Use tool (C) to remove snap ring (19) from the cartridge housing. 17. Use tool (C) to remove snap ring (20).18. Remove bearing (21) and washer.19. Use tool (C) to remove last snap ring.Assemble Turbocharger
1. Make sure all of the oil passages in the turbocharger cartridge housing, backplate assembly and bearings are clean and free of dirt and foreign material.2. Put clean engine oil on all parts of the cartridge at assembly.3. Use tool (A) to install snap ring (1) in the turbine end of the cartridge housing. 4. Install washer (2) and bearing (3). Use tool (A) to install snap ring (4) to hold the washer and bearing in position. Make sure the round edge on the outside diameter of the snap ring is toward the bearing when the snap rings are installed. 5. Use tool (A) to install snap ring (5) in the cartridge housing.6. Install washer (6). 7. Push bearing (7) into the cartridge housing until washer (6) makes contact with snap ring (5).8. Install thrust bearing (8) over the dowels in the cartridge housing. Make sure the grooves in bearing (8) are toward the outside as shown. 9. Put thrust collar (10) in position on the thrust bearing with the counterbore for the spacer up.10. Install O-ring seal (9) in the groove of the cartridge housing. 11. Install seal rings (11) on spacer (12) so the gaps in the rings are 180° apart. 12. Install spacer (12) in backplate assembly (13). 13. Make sure the oil passage in the cartridge housing and the oil passage in the backplate assembly are in alignment. Put backplate assembly (13) in position on the cartridge housing (14). Make sure the spacer fits correctly in the counterbore of the thrust collar.14. Install the locks and bolts to hold backplate assembly (13) to the cartridge housing (14). Tighten the bolts to a torque of 10 1 N m (90 9 lb.in.) and bend the tabs of the locks on the bolts. 15. Put the turbine shaft in position in tooling (B). Put 6V2055 High Vacuum Grease in the groove for seal ring (15). Make sure the grease fills the groove approximately one half or more of the groove