0434496 JOHNSON MOTOR & O-RING AY

2. Loosen two clamps (1) that hold air inlet hose assembly (2) to the turbocharger and the air cleaner housing. Remove air inlet hose assembly (2). 3. Loosen two bolts (3) on the clamp assembly. Remove clamp (5). Slide exhaust pipe assembly (4) off of the turbine housing of the turbocharger and the muffler. Remove the exhaust pipe assembly from the machine. 4. Place a drain pan under the turbocharger. A small amount of oil will drain from the oil supply tube assembly and the oil drain tube assembly when they are disconnected from the turbocharger.5. Loosen two clamps (7) and slide hose assembly (8) off of the compressor housing of the turbocharger.6. Remove oil supply tube assembly (6) and the gasket.7. Remove oil drain tube assembly (14) and the gasket. Remove the O-ring seal from the end of the oil drain tube assembly.8. Remove four nuts (9) that hold the turbocharger to the exhaust manifold. Remove turbocharger (13) and the gasket from the exhaust manifold.9. Loosen the clamp, and remove turbine housing (10) from the cartridge group.10. Remove six bolts (12) and compressor housing (11) from the cartridge group. The following steps are for the installation of the turbocharger.
Make sure the turbine housing and the compressor housing are positioned correctly on the cartridge group. Do not over-tighten the mounting bolts or clamp that hold the turbine housing and compressor housing to the cartridge group.
11. Position compressor housing (11) and turbine housing (10) on the cartridge group. Install six bolts (12) which hold the compressor housing in position. Tighten the six bolts to a torque of 7.3 0.5 N m (65 5 lb in). Tighten the clamp that holds turbine housing (10) in position to a torque of 15.8 0.5 N m (140 5 lb ft).12. Check the condition of the gasket used between the turbocharger and the exhaust manifold. If the gasket is damaged, use a new part for replacement.13. Apply 5P-3931 Anti-Seize Compound on the threads of the turbocharger mounting studs.14. Put the gasket and turbocharger (13) in position on the exhaust manifold. Install four nuts (9) that hold the turbocharger in position. Tighten the four nuts to a torque of 54 5 N m (40 4 lb ft).15. Check the condition of the gasket and O-ring seal used with oil drain tube assembly (14). If the gasket and seal are damaged, use new parts for replacement.16. Install the O-ring seal on the end of oil drain tube assembly (14). Install oil drain tube assembly (14) with the gasket.17. Check the condition of the gasket used with oil supply tube assembly (6). If the gasket is damaged, use a new part for replacement.18. Install oil supply tube assembly (6) with the gasket.19. Slide hose assembly (8) on the compressor housing of the turbocharger. Tighten two clamps (7) that hold the hose assembly in position.20. Install exhaust pipe assembly (4) between the turbine housing of the turbocharger and the muffler. Install clamp (5) that holds the exhaust pipe to the turbine housing. Tighten two bolts (3) on the clamp assembly that holds the exhaust pipe assembly to the muffler.21. Connect air inlet hose assembly (2) to the air cleaner housing and the turbocharger. Install two clamps (1) that hold the air inlet hose assembly in position. Refer to the Topic "Lubricant Viscosities and Refill Capacities" in the "Operation and Maintenance Manual" for the proper filling procedure and the proper levels for the engine.22. Check the oil level in the engine. Fill the engine with oil to the correct level.