0434891 JOHNSON LINK, Carburetor

2. Disconnect hoses (1) and remove tube assembly (2) from the turbocharger. Put caps or plugs in all the openings. 3. Remove tube assembly (3) and the elbow as a unit from the elbow on the flywheel housing. 4. Loosen clamp (4) and remove elbow (5) from the muffler and the turbocharger. 5. Disconnect tube (6) from the elbow. 6. Remove bolts (8), the washers and elbow (7) from the turbocharger and the aftercooler. 7. Install a 3/8"-16 NC forged eyebolt (11) in the turbocharger. Fasten a hoist to turbocharger (10) as shown.8. Loosen the clamp and disconnect hose (9) from the turbocharger.9. Remove the bolts and the nuts that hold turbocharger (10) to the manifold. Remove turbocharger (10) from the engine. The weight of the turbocharger is 25 kg (55 lb.).Install Turbocharger
1. Install a 3/8"-16 NC forged eyebolt (2) in turbocharger (3). Fasten a hoist to turbocharger (3). Install the gasket and the turbocharger on the manifold. Put 5P3931 Anti-Seize Compound on the threads of the bolts. Install the bolts and the nuts that hold the turbocharger to the manifold. Tighten the bolts to a torque of 55 5 N m (41 4 lb.ft.).2. Connect hose (1) to the turbocharger and tighten the clamp. 3. Put O-ring seals (4) in position on elbow (5). If necessary, put clean oil on the O-ring seals and in the bore of the turbocharger.4. Make sure the gasket is in position on the aftercooler and install elbow (5) on the turbocharger and the aftercooler. 5. Install elbow (6) on the turbocharger and the muffler and tighten clamp (7). 6. Install O-ring seal (9) on tube assembly (8).7. Put gasket (10) in position and install tube assembly (8) and the elbow as a unit. Put 5P3413 Pipe Sealant with Teflon on the threads of the bolts and install them in the elbow. 8. Put the gasket in position on the turbocharger and install tube assembly (12) on the turbocharger and the tube assembly.9. Connect hoses (11) on the turbocharger.10. Connect the tube on elbow (5).11. Connect the governor control rotochamber and the brackets on the side of the governor. See Install Governor.Disassemble Turbocharger
START BY:a) remove turbocharger 1. Put alignment marks on the cartridge, turbine housing (1) and compressor housing (3) for correct alignment and installation at assembly.2. Loosen clamps (2) and make a separation of housings (1) and (3) from the cartridge. 3. Put the cartridge in position on tool (A) as shown.4. Remove the bolts and elbow (4) from the cartridge.
To prevent possible damage to the shaft, do not put a side force on the shaft when the nut is loosened.
5. Use tool (B) and a universal socket to remove the nut from the shaft. Shaft and wheel assembly (5) are free to fall after they are removed from the cartridge.6. Use a press to push shaft and wheel assembly (5) from the cartridge and the wheel. 7. Put shaft and wheel assembly (5) in position on tool (A).8. Remove ring (6) and shroud (7) from shaft and wheel assembly (5). 9. Remove spacer (8) from the backplate assembly. 10. Remove rings (9) from spacer (8). 11. Bend the lock away from bolts (10). Remove the bolts, the locks and backplate assembly (11) from the housing assembly. 12. Remove collar (12) from the housing assembly. 13. Remove bearing (13) and ring (14) from the housing assembly. 14. Remove bearing (15) and the washer from the housing assembly. 15. Use tool (C) and remove snap ring (16) from the housing assembly. 16. Use tool (C) to remove snap ring (17). Remove bearing (18) and washer (19) from the housing assembly. 17. Use tool (C) and remove snap ring (20) from the housing assembly.Assemble Turbocharger
1. Make sure all oil passages are open and clean.
There is a round edge on the outside diameter of the snap rings used to hold the bearings in position in the turbocharger. The snap rings must be installed with the round edge toward the bearings.
2. Put clean engine oil on all parts. 3. Use tool (A) and install lower snap ring (1) in the housing assembly. 4. Install washer (4) and bearing (3). Use tool (A) to install snap ring (2). 5. Use tool (A) and install snap ring (5) in the housing assembly. 6. Put washer (7) and bearing (6) in position in the housing assembly as shown. 7. Make an alignment of pins (9) with the hole and the notch in bearing (10). Install bearing (10) on the housing assembly.8. Install seal (8) on the housing assembly. 9. Put collar (11) in position on the bearing as shown. 10. Put backplate assembly (12) in position on the housing as shown and install the locks and the bolts. 11. Tighten bolts (13) that hold the backplate assembly to the housing to a torque of 10 1 N m (89 9 lb.in.).12. Bend locks (14) against the flat side of the bolt heads. 13. Install rings (16) on spacer (15). 14. Install spacer (15) in the backplate assembly. 15. Put shaft and wheel assembly (17) in position on tool (B).
Typical Example 16. Install shroud (18) on the shaft and wheel assembly.17. Put 6V2055 High Vacuum Grease in the groove for ring (19). Make sure the grease fills the groove approximately half its depth and complete around the circumference. This will make a carbon dam under the ring. Use tool (C) to install ring (19) in the groove of wheel assembly (17). 18. Put the cartridge and wheel (20) in position on shaft and wheel assembly (17) as shown. 19. Put clean engine oil on the threads of the shaft and the nut face of wheel (20). Install the nut on the shaft and use the procedure which follows to tighten it.