0436947 JOHNSON POWERHEAD GASKET SET

1. Remove two nuts and four washers (3). Remove two nuts, washers and bolts (2). Remove shield (1). 2. Remove two bolts and washers (4) that hold the oil inlet line to the turbocharger. Remove oil inlet line (5).3. Remove two bolts and washers (6) that hold oil return line (7) to the turbocharger. 4. Fasten hoist to the turbocharger. Remove four nuts, washers and bolts (9). Remove turbocharger (8). Weight of turbocharger is 50 lb. (23 kg).Install Turbocharger
Check O-ring seals and gaskets. If damaged, use new parts for replacement. Put lubricant on O-ring seals. 1. Fasten hoist to the turbocharger. Put turbocharger (1) in position on the exhaust manifold. Put 9M3710 Anti-Seize Compound on the threads of the bolts that hold the turbocharger to the exhaust manifold. Install four bolts, washers and nuts. 2. Put oil return line (3) in position and install two washers and bolts. Put oil inlet line (2) in position and install the two washers and bolts. 3. Put shield (4) in position. Install bolts, washers and nuts that hold the shield in position.end by:a) install hoodDisassemble Turbocharger
start by:a) remove turbocharger 1. Install turbocharger in tool group (A). Put marks on the three housings of the turbocharger for correct installation and alignment at assembly. Remove "V" clamp (2) and compressor housing (1). 2. Remove "V" clamp (3). Remove the cartridge housing (5) from the turbine housing (4). 3. Install tool (C) in tool (B) and put the cartridge assembly in tool (C) as shown. Use tool (D) to remove the nut that holds compressor wheel (6).
When the nut is loosened, do not put a side force on the shaft.
The oil used to heat the compressor wheel must have a flash point (the temperature at which the oil will burn) above 400°F (204°C).
4. Install tool (H) on tool (E). Heat tool (E) to 350 25°F (177 14°C). Install the cartridge assembly on tool (H) so that only the compressor wheel is in the oil. Heat the compressor wheel for no more than 10 minutes.
Do not let the turbine wheel hit the bottom of the press.
5. Install tool (H) on tool (G). Put the cartridge assembly in tool (H) as shown. Remove compressor wheel (6) with an arbor press and tool (F). Step 5 must be done before the compressor wheel becomes cooler. 6. Put the turbine wheel in tool (C). Remove seal ring (8) and shroud (7) from the shaft. 7. Bend the tabs of the locks from bolts (10) and remove the bolts and locks.8. Remove backplate assembly (11) from the cartridge housing. Remove spacer (9) from backplate assembly (11). Remove the seal rings from spacer (9).9. Remove the collar from behind backplate assembly (11). 10. Remove thrust bearing (13) and O-ring seal (12) from the cartridge housing. 11. Remove top bearing (14) and the washer from the cartridge housing. Put a long dye mark on the top face of bearing (14). 12. Use tool (J) and remove the two rings that hold top and bottom bearings in position. Remove the bottom bearing and washer. Put a short dye mark on the bearing. The dye marks are used for identification of the bearings when they are installed.13. Use tool (J) and remove the last ring that holds the bottom bearing in position from the cartridge housing.14. Check all the parts of the turbocharger for damage. If the parts have damage, use new parts for replacement. See SPECIAL INSTRUCTION FORM NO. SMHS6854 for TURBOCHARGER RECONDITIONING. Also see GUIDELINE FOR REUSABLE PARTS FORM NO. SEBF8018.Assemble Turbocharger
1. Make sure that all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material.2. Put clean engine oil on all parts of the cartridge assembly.
Rings (1), (4) and (5) must be installed with the round edge of the rings toward the bearings.
3. Install ring (4) in the cartridge housing with tool (A).4. Install washer (3) and bearing (2) in the cartridge housing. Make sure the short dye mark on bearing (2) is up.5. Install rings (1) and (5) in the cartridge housing with tool (A). 6. Install tool (D) in tool (C). Install turbine shaft (6) in tool (D). Install seal ring (7) and shroud (8) on turbine shaft (6). 7. Install turbine shaft (6) in the cartridge housing.
Make sure the seal ring on turbine shaft (6) is fitted correctly in the cartridge housing.
8. Install washer (12), bearing (11) with the long dye mark up, thrust washer (10) with the three lubrication grooves up and O-ring seal (9) in the cartridge housing. 9. Install the seal rings on spacer (13). Install spacer (13) in backplate assembly (15). Make sure the chamfer end of spacer (13) is toward the inside of the cartridge assembly when the backplate assembly is installed.10. Install collar (14) and backplate assembly (15) on the cartridge assembly with the oil hole in the backplate assembly in alignment with the oil hole in the cartridge housing. 11. Install the locks and bolts (16) that hold backplate assembly (15) in position. Tighten the bolts to a torque of 90 10 lb.in. (10.2 1.1 N m). Some compressor wheels can be installed at room temperature. If the compressor wheel will go on the turbine shaft freely to within .31 in. (7.9 mm) of the seal ring spacer, the compressor wheel can be installed at room temperature. Compressor wheels that must be heated for assembly have a longer length of tight (interference) fit on the turbine shaft. The procedure for the installation of the compressor wheel at room temperature is the same as the procedure for installation hot except the compressor wheel is not heated.12. Use tool (B) to heat the compressor wheel in oil for no more than 10 minutes. The temperature of the oil must be 350 25°F (177 14°C). 13. Immediately after the compressor wheel is removed from the oil, put the wheel on the turbine shaft. Install the nut on