0211199 JOHNSON OWNERS MANUAL

Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-5597 Anti-Seize Compound 1
B 365-8434 Turbocharger Alignment Tool 1
343-5908 V-Band Clamp 1
343-5907 V-Band Clamp 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g06366734
Ensure that turbocharger (11) 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.
If necessary, follow Step 2a through Step 2b to install bracket (27) onto the cylinder block.
If necessary, install studs (29) (not shown) to the cylinder block. Tighten the studs to a torque of 18 N m (159 lb in).
Position bracket (27) onto studs (29). Install nuts (28) hand tight.
Illustration 2 g06372847
If necessary, install studs (26) to turbocharger (11). Tighten the studs to a torque of 18 N m (159 lb in).
Position turbocharger (11) onto bracket (27).
Loosely install nuts (30) on to studs (26).
Move turbocharger (11) in the Direction (C) to ensure that studs (26) of turbocharger (11) is positioned in the most forward position in the holes in bracket (27).
Illustration 3 g06367077
Illustration 4 g06367142
Use Tooling (B) to align the second stage turbocharger and the first stage turbocharger. 3Note: Ensure that the bracket for the turbocharger is correctly positioned onto the turbocharger and the cylinder block.
Tighten nuts (28) to a torque of 44 N m (32 lb ft). Tighten the nuts in the sequence that is shown in Illustration 3.Tighten nuts (30) to a torque of 44 N m (32 lb ft). Tighten the nuts in the sequence that is shown in Illustration 4.
Remove Tooling (B).
Illustration 5 g06366673
Illustration 6 g06372028
Remove plugs and caps from tube assembly (14) and tube assembly (23). Ensure that the tube assemblies are clean and free from damage. Replace any damaged components.
Install a new gasket (21) (not shown) onto tube assembly (23).
Position a new gasket (24) (not shown) onto tube assembly (23).
Illustration 7 g06372851
Remove the plug from the drain port (E) of the turbocharger. Remove the plug from the cylinder block.
Position tube assembly (23) onto the cylinder block and install bolts (25) finger tight.
Position tube assembly (23) onto turbo charger (11) and install bolts (22) finger tight.
Tighten bolts (22) and bolts (25) to a torque of 22 N m (195 lb in).
Remove the plug from oil inlet port (D) for turbocharger (11). Lubricate the turbocharger bearings with clean engine oil through oil inlet port (D). Rotate the wheel of the compressor several times to lubricate the bearings.
Illustration 8 g06366281
Position a new gasket (13) (not shown) onto tube assembly (14A) and install bolts (15).Note: Holes in the gasket have serration that hold the bolts captive.
Remove the plug from oil filter base (17) for the oil feed tube assembly (14A).
Illustration 9 g06366697
Position tube assembly (14A) onto turbocharger (11). Align tube nut (16) on the oil filter base (17). Tighten bolts (15) and tube nut (16) finger tight.
Install bolt (18) and bolt (20) into clamps (19), tighten the bolts (18) and bolt (20) finger tight.
Tighten bolts (15) to a torque of 22 N m (195 lb in). Tighten tube nut (16) to a torque of 45 N m (33 lb ft). Refer to Illustration 8.