0435391 JOHNSON LOCATING BRACKET

1. Remove three bolts and nuts (2) that hold elbow (1) to the exhaust manifold. Remove the elbow. Remove the seal ring from the groove in the coupling on the turbocharger. Check the condition of the seal. If the seal has damage, use a new part for replacement. 2. Loosen two clamps (4) and slide hose (3) off the turbocharger. Loosen two clamps (5) and slide hose (6) off the turbocharger. 3. Remove oil supply tube (7).4. Remove oil drain tube assembly (9) from the turbocharger.5. Remove four bolts (10) and nuts. Remove turbocharger (8) from the exhaust manifold.Install Turbocharger
1. Put a new gasket (2) for the turbocharger in position on the exhaust manifold.2. Put 5P3931 Anti-Seize Compound on the threads of the four bolts that hold the turbocharger to the exhaust manifold.3. Put turbocharger (1) in position on the exhaust manifold and install the four bolts and nuts that hold it. Tighten the bolts to a torque of 55 5 N m (40 4 lb. ft.). 4. Install a new gasket and drain tube assembly (6).5. Install a new gasket and oil supply tube assembly (4).6. Slide hose (3) in position on the turbocharger and install the clamps that hold it.7. Slide hose (5) in position on the turbocharger and install the clamps that hold it. 8. Install a new seal ring (7) in the groove on the coupling.9. Put 5P3931 Anti-Seize Compound on the threads of the three bolts that hold elbow (8) to the exhaust manifold. Install elbow (8).end by:a) install hood, muffler and precleaner assemblyDisassemble Turbocharger
start by:a) remove turbocharger 1. Install turbocharger on tool group (A). Put marks on the three housings of the turbocharger for correct installation and alignment at assembly.2. Remove eight bolts (1) and lockwashers. Remove four plates and compressor housing (2). 3. Remove two locks, two plates and four bolts (3) that hold the cartridge housing to the turbine housing. Remove cartridge housing (4).
When the nut is loosened, do not put a side force on the shaft.
4. Put the cartridge assembly on tool (B) as shown. Use tool (C) and the correct size socket to remove the nut that holds compressor wheel (5) on the shaft. 5. Hold the cartridge assembly down in tool (B) and lift and turn the compressor wheel (5) at the same time to remove it from the shaft. 6. Remove cartridge assembly (6) from the shaft. 7. Remove bearing (7) and ring (8) from the shaft. 8. Remove ring (9) from the housing assembly with tool (D). 9. Remove the insert, sleeve and deflector from the housing assembly as a unit. Use two screwdrivers to remove the unit. 10. Remove O-ring seal (14) from insert (13). Remove sleeve (10) from the insert and deflector (11). Remove ring (12) from the sleeve. 11. Remove bearing (15) from the housing assembly. 12. Turn the housing assembly over. Remove shroud (16) and the gasket from the housing assembly.Assemble Turbocharger
1. Make sure that all of the oil passages in the cartridge housing assembly are clean and free of dirt and foreign material. Put clean oil on all the parts of the cartridge assembly. 2. Put shaft (1) in position in tool (A). Install ring (3) and bearing (2) in the shaft as shown. 3. Put shroud (4) in position on the shaft as shown. 4. Put gasket (6) in position on the shroud. Install housing assembly (5) over the shaft. 5. Install bearing (7) in the housing assembly. Make sure the bronze side of the bearing is up. 6. Put deflector (9) in position over sleeve (8).7. Install ring (10) in the groove on the sleeve. Push the sleeve into insert (11). Install O-ring seal (12) on the insert. 8. Install the insert, deflector and sleeve as a unit in the housing assembly as shown. 9. Install ring (13) in the groove in the housing assembly with tool (B). 10. Put compressor wheel (14) in position on the shaft.
Do not put a side force on the shaft when the nut that holds the compressor wheel in position is tightened.
TYPICAL EXAMPLE11. Install the nut that holds the compressor wheel in position. Tighten the nut to a torque of 18.7 1.7 N m (165 15 lb. in.). 12. Put turbine housing (15) in position on tool (C). Put cartridge assembly (16) in position in the housing. Make sure the mark on the cartridge assembly is in alignment with the mark on the housing. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold cartridge assembly to the turbine housing. Install the two locks, two plates and four bolts that hold the cartridge assembly to the turbine housing. Tighten the bolts to a torque of 15 to 17 N m (11 to 12 lb. ft.). Bend the locks over the bolts.13. Put compressor housing (17) in position on the cartridge assembly. Make sure the mark on the housing is in alignment with mark on the cartridge assembly. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold the compressor housing to the cartridge assembly. Install the four plates and eight bolts and lockwashers that hold the compressor housing in position. Tighten the eight bolts to a torque of 6.8 N m (60 lb. in.).end by:a) install turbocharger