0434281 JOHNSON GEARCASE, Housing assy.

2. Remove bolt (1), the nut and clips (2) from the tube assemblies. 3. Loosen nut (5) and remove bolts (3), the gasket and tube assembly (4) from the turbocharger and engine block. 4. Remove bolts (6), the gasket and tube assembly (7) from the turbocharger and engine. 5. Loosen hose clamps (8) and (10).6. Remove bolts (11), the nuts, turbocharger (9) and the gasket from the engine. The following steps are for the installation of the turbocharger.7. Put the gasket and turbocharger (9) in position as shown. Install the bolts and nuts that hold the turbocharger to the exhaust manifold. Put 5P3931 Anti-Seize Compound on the threads of the bolts. Tighten hose clamps (8) and (10).8. Make sure the O-ring seal is in position on the bottom of tube assembly (7) and install it in the engine.9. Put the gasket in position and connect tube assembly (4) to the turbocharger.10. Install clips (2) that hold the tube assemblies together.11. Install the muffler.Disassemble Turbocharger
Start By:a. remove turbocharger 1. Put the turbocharger in position on tool (A).2. Put an alignment mark on compressor housing (1) and the backplate assembly for use at assembly. Remove the compressor housing from the backplate assembly. 3. Change the position of tool (A) so the compressor wheel is up as shown.4. Put an alignment mark on housing (2) and turbine housing (3) so that the housing can be put back in the same position in the turbine housing at assembly.5. Remove the bolts, lockplates and clamps that hold the housing in the turbine housing, and remove housing (2). 6. Put the housing in position on tool (B).
Do not put a bending force on the shaft when the nut is removed.
7. Use tool (C) and a socket of the correct size to remove nut (5) from the shaft.8. Remove compressor wheel (4) from the shaft. 9. Remove the housing from the shaft.10. Remove shroud (6) from the turbine wheel and shaft. 11. Remove seal ring (7) from the turbine wheel. 12. Put a mark on the housing and backplate assembly for use at assembly. Remove the bolts and plates that hold the housing to the backplate assembly. Remove the housing.13. Remove bearing (8), collar (9) and the seal ring from backplate assembly (10).14. Remove the seal ring and bearing from the collar. 15. Remove seal ring (11) from the housing.16. Remove the snap ring, bearing (12) and the snap ring from each side of the housing.Assemble Turbocharger
1. Make sure all oil passages are clean and free of all dirt or foreign material. Put clean engine oil on all of the parts before assembly.
The snap rings must be installed with the round outside edge side toward the bearing.
2. Install the inner snap ring, bearing (12) and snap ring (13) in each side of the housing. 3. Install the seal ring on collar (9).4. Put bearing (8) in position on the collar.
The oil groves in the bearing must be clean and free of all dirt or foreign material. The bearing must be installed with the oil grooves toward the housing.
5. Put the bearing and collar in position on the housing so the oil grooves in the bearing are toward the housing and the holes in the bearing are in alignment with the pins in the housing.
Be extra careful during installation of the bearing and collar not to cause damage to the seal ring on the collar.
6. Install the seal ring on the housing.7. Put the backplate assembly in position on the housing respective to the marks put on the housing and backplate at disassembly. Install the plates and bolts. Tighten the bolts to a torque of 8.5 to 10.2 N m (75 to 90 lb.in.). 8. Install shroud (6) on the housing. 9. Put 6V2055 High Vacuum Grease in the groove for seal ring (7). Make sure the grease fills the groove approximately one half or more of the groove depth for the complete circumference of the groove to help make a carbon dam under the seal. Use tool (D), and install seal ring (7). Carefully install turbine wheel and shaft (14) in the housing. 10. Put the housing, turbine wheel and shaft and the backplate assembly in position on tool (B). 11. Install compressor wheel (4) on the turbine shaft.12. Use the procedure which follows to install and tighten the nut which holds the compressor wheel in position.
Do not put a bending force on the shaft and wheel assembly when the nut is loosened or tightened.
a. Put a small amount of clean engine oil on the threads and impeller face surface that makes contact with the nut. Install the nut.b. Tighten the nut to a torque of 2.3 N m (20 lb.in.). Use tool (C), and tighten the nut 100° more.c. Remove the nut from the shaft.d. Put 6V1541 Quick Cure Primer on the threads of the shaft and nut.e. Put 9S3265 Retaining Compound on the threads of the shaft and nut.f. Install the nut on the shaft, and tighten the nut to a torque of 2.3 N m (20 lb.in.). Use tool (C), and tighten the nut 100° more.
Typical Example13. Put the cartridge assembly in a vise as shown. Make sure soft (brass) jaws are used.14. Install tooling (E) on the cartridge assembly to check end play. The end play must be 0.03 to 0.10 mm (.001 to .004 in.). 15. If the turbine housing was removed from tool (B), put the turbine housing in position on tool (A).16. Put the housing and wheels in position in the turbine housing respective to the alignment marks put on the housings at disassembly. 17. Put 5P3931 Anti-Seize Compound on the threads of bolts (15). Install the clamps, lockplates and bolts (15). Tighten the bolts to a torque of 13 1.7 N m (115 15 lb.in.). Bend the lockplates against the bolt heads. 18. Put compressor housing (1) in position on the backplate assembly respective to the alignment marks put on the housing and backplate assembly