5035405 JOHNSON GROMMET, REAR CASE

Table 1
Required Tools
Tool Part Number Part Description Qty
A 5P-3975 Rubber Lubricant 1
B 4C-5597 Anti-Seize Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g03376657
Ensure that turbocharger (1) is clean and free from damage. Inspect the turbocharger for wear. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If the turbocharger is worn, the complete turbocharger must be replaced.
Test the wastegate actuator (19) for correct operation. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect". If the wastegate actuator is damaged or the wastegate actuator does not operate within the specified limits, the turbocharger assembly must be replaced.
Illustration 2 g03376117
Clean the gasket surface of exhaust manifold (14).
If necessary, install studs (15) to exhaust manifold (14). Apply Tooling (B) to the threads of studs (15). Tighten the studs to a torque of 18 N m (159 lb in).
Position turbocharger (1) on exhaust manifold (14). Note: Ensure that the turbocharger is correctly oriented.
Install nuts (16). Tighten the nuts to a torque of 44 N m (32 lb ft).
If a new turbocharger is installed, check that the orientation of compressor housing (18) is correct. Refer to Illustration 1. Follow Step 7.a through Step 7.c in order to orient the compressor housing.
Loosen band clamp (20) sufficiently in order to allow the compressor housings to rotate. Note: If the band clamp is damaged, replace the band clamp.
Rotate compressor housing (18) until the compressor outlet is in the correct position. Refer to the turbocharger that was originally installed for the correct orientation.
Ensure that band clamps (20) are correctly oriented. Refer to the turbocharger that was originally installed for the correct orientation. Tighten the band clamps finger tight.
Illustration 3 g03376116
Ensure that tube assembly (11) and tube assembly (4) are clean, free from damage, and restriction. Replace any damaged components.
Position a new gasket (6) (not shown) and bolts (8) onto tube assembly (11).
Install tube assembly (11) onto turbocharger (1). Tighten bolts (8) finger tight.
Position a new gasket (13) between the flange of tube assembly (11) and the cylinder block. Install bolts (12) finger tight.
Tighten bolts (8) and bolts (12) to a torque of 22 N m (195 lb in).
If a new turbocharger has been installed, check that the orientation of compressor housing (18) is correct. If the orientation of the compressor housing is not correct, rotate the compressor housing until correctly positioned. Refer to Illustration 1. Tighten band clamps (20) to a torque of 13 N m (115 lb in).
Remove the plug from oil inlet port (17). Refer to Illustration 1. Lubricate the turbocharger bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor several times in order to lubricate the bearings.
Use Tooling (A) in order to lubricate a new O-ring seal (7). Install the O-ring seal to tube assembly (4).
Position a new sealing washer (3) (not shown) onto banjo bolt (2). Install the banjo bolt to tube assembly (4).
Install tube assembly (4) onto turbocharger (1) and the cylinder block. Tighten banjo bolt (1) finger tight.
Install bolt (5) finger tight. Ensure that tube assembly (4) is correctly positioned into the cylinder block.
Tighten banjo bolt (1) to a torque of 20 N m (177 lb in).
Tighten bolt (5) to a torque of 22 N m (195 lb in).
Connect hose (10) to the actuator. Slide clip (9) along the hose. Ensure that the hose clip is correctly positioned.
If the turbocharger has an exhaust elbow, install the exhaust elbow. Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install" for the correct procedure.
Connect the exhaust tube assembly. Refer to the Original Equipment Manufactures (OEM) for the correct procedure.
Connect the hose assemblies to the turbocharger inlet and the turbocharger the outlet. Refer to the OEM for the correct procedure.