0115214 JOHNSON SCREW, Gearcase to exhaust housing

1. Remove bolts (2) from bracket on cylinder head.2. Remove bolt (1) from turbocharger.3. Remove air inlet pipe and air cleaner bracket as a unit. 4. Remove oil supply line (4) for turbocharger.5. Disconnect oil return line for turbocharger.6. Remove bolts (5) from turbocharger and remove turbocharger.7. Remove coupling (3) from exhaust elbow.Install Turbocharger
1. Install coupling (1) in exhaust elbow.2. Put 9M3710 Anti-Seize Compound on threads of turbocharger bolts.3. Put the turbocharger (2) in position on exhaust manifold and install bolts. Tighten bolts to a torque of 40 4 lb.ft. (5.5 0.6 mkg).4. Install supply line and connect return line for turbocharger.5. Install air inlet pipe and air cleaner bracket as a unit.end by: a) install air cleaner housingDisassemble Turbocharger
start by: a) remove turbocharger 1. Put the turbocharger in position on tool (A).2. Put a mark on the compressor cover and housings for installation purpose.3. Remove "V" clamp (2) and remove compressor cover (1). 4. Remove "V" clamp (3) and remove shaft housing from turbine housing (4). 5. Put shaft housing in tool (B). Remove nut and compressor wheel (5) from the shaft.
When loosening the nut, do not put a side force on the shaft.
6. Remove shaft housing from tool (B) and remove turbine wheel (7) and shaft from housing.7. Remove seal ring (6) from the turbine wheel. 8. Remove snap ring and insert (8) from the housing. 9. Push the sleeve (9) out of the insert. Remove the two seal rings from the sleeve. 10. Remove deflector (10), ring (15), sleeve (11), bearing (12), ring (16), snap ring (13), bearing (17) and snap ring (14) from the housing. Remove snap rings (13) and (14) with tool (C). Check the oil hole in bearing (12). If the oil hole is not open this will cause a bearing failure. 11. Turn the housing around and remove snap ring (18) and shroud (22).12. Remove snap ring (19), sleeve (20), bearing (21), and snap ring (23). Remove the two snap rings with tool (C).13. Inspect all parts and install new parts as needed.Assemble Turbocharger
1. Make sure all oil passages are open and clean. Put clean engine oil on all parts before assembly. 2. Install snap ring (4), bearing (3), sleeve (2) and snap ring (1). Install the two snap rings with tool (A). Install the snap rings with the round side toward the bearing. 3. Install shroud (5) on the housing. Turn the shroud to make sure it is down on the housing even. The high part (web) (6) on shroud, will keep the shroud from turning on the housing after assembly.4. Install snap ring that holds the shroud in place.5. Install the bearing and two snap rings in the compressor end of the housing. Install the snap rings with tool (A). Install the snap rings with the round side toward the bearing. 6. Install seal ring (7) on the shaft. Install turbine wheel (8) and shaft in the housing.7. Put housing in position on tool (B). 8. Install ring (13), bearing (11), sleeve (12), ring (10) and deflector (9) in the housing.
The oil hole in bearing (11) must be open and clean.
9. Install the seal rings on sleeve (15). Install sleeve in insert (14). 10. Install insert in the housing and install snap ring (17).11. Install compressor wheel (16) on shaft. 12. Put clean engine oil on the threads of the shaft. Install the nut (18) and tighten to a torque of 15 1 lb.ft. (2.1 0.14 mkg).
When tightening nut do not put a side force on the shaft.
13. Install shaft housing into the turbine housing. Install "V" clamp (21) and tighten clamp to a torque of 120 lb.in. (138.4 cm.kg).14. Install compressor cover (19) and "V" clamp (20). Tighten "V" clamp to a torque of 120 lb.ft. (138.4 cm.kg).end by: a) install turbocharger