5034308 JOHNSON **KEY (935)

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Guide Studs
M10 by 80 mm 2
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.Keep all parts free from contaminants. Contaminants may cause rapid wear and shorten component life.Plug or cap all open ports and tube assemblies.
Illustration 1 g02568277
Loosen hose clamps (2) and disconnect hose assembly (1) from the outlet of turbocharger (5).
Loosen hose clamp (4) and disconnect air inlet hose (3) from the turbocharger.
Remove the exhaust back pressure valve (9). Refer to Disassembly and Assembly, "Exhaust Back Pressure Valve - Remove and Install" for the correct procedure.
Slide hose clamp (7) along hose assembly (6). Disconnect hose assembly (6) from wastegate actuator (8).
Illustration 2 g02568281
Remove banjo bolt (10). Disconnect tube assembly (12) from the turbocharger.
Remove sealing washers (11).
Remove bolts (14).
Disconnect tube assembly (15) from the turbocharger.
Remove gasket (13) from tube assembly (15). Note: Plug or cap all open ports with new plugs or caps.
Illustration 3 g02563836
Illustration 4 g02563838
Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.
Slide hose clip (18) along hose assembly (19). Disconnect the hose assembly from tube assembly (17).
Remove bolts (16) and bolt (20).
Remove tube assembly (17) from the cylinder block.
Apply releasing fluid prior to and during the removal of bolts (21).
Remove bolts (21) from tube assembly (22). Discard bolts (21).
Remove bolts (26) and bolts (32). Remove tube assembly (28) from the exhaust cooler and from the cylinder head.
Remove gasket (27) (not shown) and gasket (31) (not shown).
Loosen bolts (33) in order to allow removal of tube assembly (25).
Remove bolts (23) and bolts (29). Remove tube assembly (25) from the exhaust cooler and induction mixer. Note: The bolts for the tube assembly are different lengths. Make a note of the location of the bolts in order to ensure that damage to components does not occur during assembly.
Remove gasket (24) (not shown) and gasket (30) (not shown).
Illustration 5 g02560019
Illustration 6 g03423121
Typical example
Turbo removed for clarity.
If necessary, position the dipstick tube assembly (39) away from exhaust manifold (38) in order to create sufficient clearance to allow removal.
Loosen bolts (37) in reverse numerical order. Refer to Illustration 6. Note: Loosening the bolts in reverse numerical order will help prevent distortion of the exhaust manifold.
Remove bolts (37) and spacers (34) from exhaust manifold (38) in Position (V) and Position (Y).
Insert Tooling (A) in Position (V) and Position (Y).
Remove the remaining bolts (37) and spacers (34) from exhaust manifold (38). Note: Support the exhaust manifold and turbocharger as the bolts are removed.
Remove exhaust manifold (38).
Remove Tooling (A) from the cylinder head.
Remove exhaust manifold gasket (35) (not shown) and exhaust manifold gasket (36) (not shown).
Illustration 7 g02563397
If necessary, remove adapter (40) from the turbocharger. Refer to Disassembly and Assembly, "Exhaust Back Pressure Valve - Remove and Install" for the correct procedure.
Remove gasket (47) from tube assembly (46).
If it will be necessary to remove bolts (45), apply releasing fluid prior to and during the removal of the bolts. Remove bolts (45) from the exhaust manifold. Remove the tube assembly (46). Remove gasket (44) from the tube assembly.
Remove nuts (41).
Remove the turbocharger from exhaust manifold (38).
Remove gasket (42) from the exhaust manifold.
If necessary, remove studs (43) from the exhaust manifold.