0436242 JOHNSON PISTON, Std., port

2. Remove the platform from above the engine. 3. Loosen the clamps from the hoses and elbows on each end of turbocharger inlet tubes (1).4. Disconnect the wire from sensor (2).5. Disconnect hose (3).6. Remove the clamps from two support brackets (4).7. Remove turbocharger inlet tubes (1). 8. Fasten a hoist to exhaust pipe (6). Remove nut (9) and clamp (7) that fastens the exhaust pipe to the turbocharger.9. Remove four bolts (5) and remove exhaust pipe (6) from the engine. The weight of exhaust pipe (6) is 23 kg (50 lb.).10. Remove heat shields (8) and (10) from below the turbocharger. 11. Remove the two water lines and the two oil lines from the turbocharger.12. Remove two bolts (14) and remove support (13) and adapter (11) from the turbocharger.13. If necessary, remove bolts (12) and remove adapter (11) and the gasket from support (13).14. Fasten a hoist to the turbocharger. Remove four bolts (15). Remove the bolt and washer that fastens pipe (16) to the turbocharger. Remove the turbocharger from the engine. The weight of the turbocharger is 32 kg (70 lb.).15. Install the turbochargers in the reverse order of removal.16. Be sure all parts are clean and the mating surfaces are smooth. Use all new gaskets and seals. Lubricate the seals on pipe (16) with glycerin.17. Put 5P3931 Anti-Seize Compound on the threads of bolts (12), (14) and (15).18. Tighten bolts (14) and (15) to a torque of 55 7 N m (41 5 lb. ft.).20. Put exhaust pipe (6) in position, and rotate the three sections of exhaust pipe (6) until the best alignment is obtained between the turbochargers and the frame.21. Install clamp (7) and tighten nut (9) to a torque of 15 3 N m (10 2 lb. ft.). Tap lightly all around clamp (7) with a soft hammer and tighten nut (9) again. Repeat as necessary.22. Fill the radiator to the correct level with coolant. Refer to the Operation and Maintenance Manual for further information.Disassemble Turbochargers
Start By:a. remove turbochargers 1. Put the turbocharger in position on tool group (A) as shown.2. Put marks on the housings of the turbocharger for correct installation and alignment at assembly.3. Loosen clamp (2) and remove compressor housing (3) and clamp (2) from the cartridge assembly. 4. Loosen clamp (4) and remove cartridge assembly (5) from turbine housing (6).
To prevent a bent shaft, do not put a side force on the turbine shaft when the compressor wheel nut is loosened.
5. Put the end of the turbine shaft in tooling (B). Use a universal joint and socket of the correct size to remove the nut that holds compressor wheel (7) on the turbine shaft. 6. Use a press and push the turbine shaft out of compressor wheel (7) and the cartridge housing. Remove compressor wheel (7) from the cartridge housing. 7. Remove shroud (9) from turbine shaft (8). 8. Remove seal ring (10) from turbine shaft (8). 9. Bend the tabs of the locks from bolts (11) and remove the bolts.10. Remove backplate assembly (12) from the cartridge housing. Make a note of the position of the oil holes in the backplate assembly and cartridge housing for correct alignment at assembly. 11. Push spacer (13) out of the bore in backplate (12). 12. Remove seal rings (14) from spacer (13). 13. Remove seal (15) from the cartridge housing. 14. Remove thrust collar (16) from the cartridge housing. 15. Remove thrust bearing (17) from the cartridge housing. If the bearings are to be used again, put identification on them as to their location for correct assembly.16. Remove bearing (18) from the cartridge housing. 17. Remove washer (19) from the cartridge housing. 18. Remove snap rings (20) and (21) with tooling (C). 19. Remove bearing (22) from the cartridge housing. 20. Remove washer (23) from the cartridge housing. 21. Remove snap ring (24) from the cartridge housing with tooling (C). 22. Turn the cartridge housing over. Remove plates (25) from the cartridge housing.Assemble Turbochargers
Use the following procedures to assemble the turbocharger. Also refer to Specifications Manual SENR5189 for additional information.1. Check the turbocharger cartridge housing, backplate assembly and bearings to make sure all oil passages are clean and free of dirt and foreign material.2. Put clean engine oil on all parts of the cartridge at assembly. 3. Install plates (1) on the cartridge housing. Turn the cartridge housing over. Make sure the round edge on the outside diameter of the snap ring is toward the bearing when the snap rings are installed.4. Install snap ring (2) in the turbine end of the cartridge housing with tool (A). Install washer (4) and bearing (3). 5. Install snap ring (5) in the cartridge housing with tool (A) to hold the washer and bearing in place. 6. Install snap ring (6) in the cartridge housing with tool (A).7. Install washer (8) and bearing (7) in the cartridge housing until washer (8) makes contact with snap ring (6). 8. Install thrust bearing (9) over the dowels in the cartridge housing. Make sure the grooves in bearing (9) are toward the outside as shown. 9. Put thrust collar (10) in position on the thrust bearing with the counterbore for the spacer up. 10. Install seal ring (11) in the groove of the cartridge housing. 11. Install seal rings (12) on spacer (13) so the gaps in the seal rings are 180° apart. 12. Install spacer (13) in backplate assembly (14). 13. Make sure the oil passage in the cartridge housing and the oil passage in the backplate assembly are in alignment. Put backplate assembly (14) in position on the cartridge housing. Make sure the spacer fits correctly in the counterbore of the thrust collar.14. Install the locks and bolts to hold backplate assembly (14) to the cartridge housing. Tighten the bolts to a torque of 10 1 N m (90 9 lb. in.) and bend the tabs of the locks on the bolts. 15. Put turbine