0211198 JOHNSON OWNERS MANUAL

Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-5597 Anti-Seize Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g06368233
Ensure that turbocharger (3) is clean and free from damage. Inspect the turbocharger for wear. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If any part of the turbocharger is worn or damaged, the complete turbocharger must be replaced.
Test wastegate actuator (32) for correct operation. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If any part of the wastegate actuator (32) is worn or damaged, the complete turbocharger must be replaced.
Illustration 2 g06368135
Clean the gasket surface of exhaust manifold (28). If necessary, install studs (31) to turbocharger (3). Tighten the studs to a torque of 18 N m (160 lb in).
Install a new gasket (30) to studs (31).
Position turbocharger (3) onto the exhaust manifold and install nuts (29) finger tight. The nuts (29) should not prevent the turbocharger from correctly positioning the turbocharger onto the exhaust manifold.Note: Ensure that the turbocharger is correctly oriented.
Illustration 3 g06368245
Turbocharger tightening sequence viewed from the exhaust manifold.
Tighten nuts (29) in the sequence shown in Illustration 3 to a torque of 44 N m (32 lb ft).
Illustration 4 g06372487
Illustration 5 g06367565
Remove plugs and caps from tube assembly (15) and tube assembly (18). Ensure that the tube assemblies are clean and free from damage. Replace any damaged components.
Position a new gasket (16) (not shown) onto tube assembly (18).
Illustration 6 g06368143
Install bolts (17) to tube assembly (18). Tighten the bolts to a torque of 22 N m (195 lb in).
Remove plug from oil filter base (24) for oil feed tube assembly (21).
Position tube assembly (21) onto turbocharger (19). Align tube nut (23) on oil filter base (24). Tighten bolts (22) and tube nut (23) finger tight.Note: Holes in the gasket have serration that holds the bolts captive.
Install bolt (25) and bolt (27) into clamps (26). Tighten bolts (25) and bolt (27) finger tight.
Tighten bolts (22) to a torque of 22 N m (195 lb in). Tighten tube nut (23) to a torque of 45 N m (33 lb ft).
Illustration 7 g06368254
Remove the plug from oil inlet port (X). Lubricate the turbocharger bearings with clean engine oil through the oil inlet port (X). Rotate the wheel of the compressor several times to lubricate the bearings.
Install new O-rings (14) to tube assembly (15). Install the banjo bolt (13) to tube assembly (15).
Illustration 8 g06368142
Position tube assembly (15) onto turbocharger (3) and tube assembly (21) Connect tube nut (21A) to tube assembly (21).
. Tighten the banjo bolt (13) to a torque of 20 N m (177 lb in) and the tube nut (21A) to a torque of 45 N m (33 lb ft).
Illustration 9 g06367509
Use Tooling (A) to lubricate the allen head bolt for V-band clamp (5). Position V-band clamp (5) onto air duct (9).
Position hose assembly (10) and air duct (9) onto the outlet of turbocharger (3) and the turbocharger (19). Ensure that V-band clamp (5) is correctly seated on the air duct (9) and turbocharger (3).
Tighten the allen head bolt for V-band clamp (5) to a torque of 12 N m (106 lb in).
Tighten hose clamps (11) to a torque of 6 N m (53 lb in).
Use Tooling (A) to lubricate the nut for V-band clamp (12). Position V-band clamp (12) onto the turbocharger (19).
Use Tooling (A) to lubricate the nut for V-band clamp (2). Position V-band clamp (2) onto elbow (1).
Position elbow (1) onto turbocharger (19) and turbocharger (3).
Tighten nuts for V-band clamp (2) and nuts for V-band clamp (12) finger tight. Ensure that the V-band clamps are seated correctly onto the turbochargers.
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