0436312 JOHNSON PISTON & PIN, 0.030 in. o.s. (port)

1. Drain the coolant from the radiator until the level is below the aftercooler. 2. Remove platform (1). 3. Loosen the clamps from the hoses and elbows on each end of turbocharger inlet tubes (2).4. Disconnect the wire from sensor (3).5. Remove the clamps from two support brackets (4).6. Disconnect hose (13).7. Remove turbocharger inlet tubes (2).
Typical Example8. Remove nut (8) and disconnect clamp (9) that fastens exhaust pipe (6) to the turbocharger. Remove four bolts (5) and remove exhaust pipes (6) from the engine.9. Remove two heat shields (7) from below each turbocharger.
Typical Example10. Remove turbocharger inlet tube support brackets (11). Remove exhaust manifold heat shields (10) and (12) over each exhaust manifold.
Typical Example11. Remove tube (14) and hose (13) from the turbochargers.12. Remove adapters (18) and pipes (16) from the aftercooler housing and turbochargers as a unit.13. Remove inside heat shields (17) and rear heat shield (15) from around the exhaust manifolds to give access to the aftercooler housing mount bolts.
Typical Example14. Remove elbow (19) from the front end of the aftercooler.15. Disconnect wires (21) from the switch below elbow (20).16. Remove elbow (20) from the rear of the aftercooler.
Typical Example17. Remove sleeve (23) and adapter (22) from each end of the aftercooler.18. Remove all bolts (24) and the spacers that fasten the aftercooler housing to the engine block.
Typical Example19. Install tooling (A) on aftercooler housing (25) and fasten a hoist. Remove the aftercooler housing. The weight of the housing is 37 kg (82 lb.).
Typical Example20. Remove bolts (27) that fasten aftercooler core (28) to the engine block. Fasten a hoist and remove the aftercooler core. The weight of the core is 31 kg (68 lb.). 21. Remove O-ring seals (29) from each end of core assembly (28).22. Remove ring (30) and connector (31) from the core assembly.23. Remove four O-ring seals (32) from the connector. The following steps are for installation of the aftercooler.
Be sure all parts are clean and free of rust before assembly. Assemble using all new seals and gaskets. Lubricate all O-ring seals with glycerin before assembly.
24. Install the aftercooler in the reverse order of removal.25. If the two halves of aftercooler housing (25) were separated, install a new gasket and assemble the two halves together. Trim the new gasket flush with the bottom of aftercooler housing (25). Apply 3S6252 Sealant to bottom of the housing, where the gasket was trimmed.26. Tighten bolts (24), that fasten the aftercooler housing to the engine block, to a torque of 55 7 N m (41 5 lb. ft.).27. Rotate the three sections of exhaust pipe (6) until the best alignment is obtained between the turbochargers and the frame.28. Install clamp (9) and tighten nut (8) to a torque of 15 3 N m (10 2 lb. ft.). Hit lightly all around clamp (9) with a soft hammer and tighten nut (8) again. Repeat as necessary.29. Reverse the procedures and steps 3 through 7 to install turbocharger exhaust tubes (2).30. Install platform (1).31. Fill the radiator with coolant. Refer to the Operation and Maintenance Manual for further information.