0115021 JOHNSON SCREW, Clamp

1. Remove four bolts (4) and nuts. Remove exhaust elbow (3).2. Remove oil supply line (6) from the turbocharger. Remove oil return line (5) from the turbocharger.3. Remove four bolts (2) and nuts.4. Remove two bolts (1) and washers from the elbow to the aftercooler.5. Fasten a hoist to the turbocharger and inlet elbow. Remove two nuts (10) and washers. 6. Remove four bolts (9) and nuts that hold the turbocharger to the exhaust manifold.7. Remove turbocharger (8) and inlet elbow as a unit. Weight of the unit is 80 lb. (36.3 kg). Remove inlet elbow (7) from the turbocharger.Install Turbocharger
1. Put clean SAE 30 oil on the seals of the inlet elbow. Install the inlet elbow on the turbocharger. 2. Fasten a hoist to the turbocharger (1). Put the unit in position on the exhaust manifold. Put 9M3710 Anti-Seize Compound on the threads of the bolts that hold the turbocharger in position. Install the four bolt and nuts. 3. Install two bolts (2) and washers.4. Install four bolts (3) and nuts.5. Install two nuts (5).6. Install oil supply line (6) and oil return line (7).7. Install exhaust elbow (4) on the turbocharger. Install the four bolts and nuts that hold it.end by: a) install hoodDisassemble Turbocharger
start by:a) remove turbocharger 1. Put the turbocharger in position on tool (A).2. Put a mark on the compressor cover and housing for installation purpose.3. Remove bolts (1) and plates from the compressor housing.4. Remove the compressor housing. 5. Remove bolts (2) and locks from the turbine housing.6. Remove cartridge (3) from the turbine housing. 7. Install tool (B) in tool (C). Install the cartridge in tool (C).8. Remove nut (4) from the compressor wheel.
When loosening the nut, do not put a side force on the shaft.
9. Install tool (D) on an oil heater. Heat the oil to a temperature of 350 25°F (177 14°C). Install the cartridge on tool (D) with only the compressor wheel in the hot oil. Keep the compressor wheel in the hot oil for ten minutes. 10. Put tool (C) and the cartridge on tool (E) under pressure. Install driver (F) and push the shaft out of the compressor wheel. Step 10 must be done before the compressor wheel gets cold.11. Remove the compressor wheel and shroud. Remove the turbine wheel and shaft. 12. Remove the four bolts (5) and locks from plate (16). 13. Remove plate (6), spacer, collar, and the thrust bearing from the cartridge.14. Remove the seal from the plate and the ring from the spacer. 15. Remove bearing (7), washer (11) and snap ring (8) from the compressor side of the cartridge.16. Remove snap ring (13), washer (10), bearing (12) and snap ring (9) from the turbine side of the cartridge.17. Inspect all of the parts and install new parts as needed.Assemble Turbocharger
1. Make sure all of the oil passages are open and clean. Put clean engine oil on all of the parts before assembly. 2. Install snap ring (6), bearing (3), washer (7) and snap ring ( snap ring (4) in the turbine side of the cartridge. Install the two snap rings with tool (A). Install the snap rings with the rounded edge toward the bearing.3. Install snap ring (2), washer (5), and bearing (1) in the compressor side of the cartridge. 4. Install seal (12) on the plate (8) and ring (9) on the spacer (11).5. Install collar (10) in the plate and spacer (11) in the collar. 6. Install thrust bearing (13) with the three radial grooves toward the outside.7. Install plate (8), bolts and locks. Tighten the bolts to a torque of 35 5 lb.in. (3.95 0.56 N m). 8. Install ring (14) on the turbine wheel.9. Install the turbine wheel and the shaft in the cartridge. Be careful not to break ring (14) when the shaft is installed. 10. Put the cartridge on tool (C) and tool (C) on tool (B).11. Install the compressor wheel as follows: a) Heat compressor wheel (15) in oil to a temperature of 350 25°F (177 14°C) for ten minutes.b) Install the compressor wheel on the shaft and install the nut. Tighten the nut to a torque of 150 lb.in. (16.95 N m). b) Let the compressor wheel cool and then remove nut (16).d) Put clean engine oil on the threads of the shaft. Install the nut and tighten it to a torque of 30 lb.in. (3.39 N m). Turn the nut 90° more. When the nut is tightened, do not put a side force on the shaft. 12. Install the cartridge in the turbine housing. Put 9M3710 Anti-Seize Compound on the threads of the bolts. Install the locks and bolts (17) in the turbine housing. Tighten the bolts to a torque of 175 5 lb. in. (19.8 0.56 N m). 13. Install the compressor housing on the cartridge. Put 8S6747 Gasket Sealer on the threads of bolts (18). Install the bolts in the compressor housing. Tighten the bolts to a torque of 105 5 lb.in. (11.86 0.56 N m).end by: a) install turbocharger