0339192 JOHNSON SEAL, Air silencer to carb.

3. Loosen clamps (1) and remove hose (2). Remove turbocharger supply and return oil lines (3). Remove the muffler. 4. Remove bolts (4), and remove elbow (5). 5. Remove bolts (6). Remove four bolts (7) and bracket (8).6. Remove elbow (10). Fasten a nylon strap and hoist to the turbocharger, and remove turbocharger (9). The weight of the turbocharger is 31.7 Kg (70 lb.).7. Remove bolt and washer (12), and remove pipe (13) from the turbocharger. The following steps are for the installation of the turbocharger.8. Inspect O-ring seals, and make a replacement of any that are damaged. Put clean oil on the O-ring seals prior to installation.9. Use a nylon strap and hoist to position the turbocharger on the exhaust manifold. Install pipe (13) on the turbocharger with bolt and washer (12).10. Loosen clamp (11) to allow proper alignment, and then tighten clamp (11).11. Install elbow (10) and tighten the two clamps that hold it.12. Install bracket (8), and the four bolts (7). Install bolts (6). Install elbow (5) with bolts (4). Install the muffler.13. Install the turbocharger supply and return oil lines (3). Install hose (2) and tighten clamps (1) that hold it.14. Install the muffler.15. Install the hood.Disassemble And Assemble Turbocharger
Start By:a. remove turbocharger 1. Install the turbocharger on tool (A).2. Put alignment marks on the three housings of the turbocharger for correct alignment during assembly. Loosen the two clamps and separate the center section (cartridge) from the two outside housings.3. Put the cartridge group (shown in the illustration) with nut (1) up in tool (B). Use a 5S9566 Sliding T-Wrench and a universal socket to remove nut (1) that holds the compressor wheel (2) to the wheel assembly (11).4. Remove compressor wheel (2), shims (3), and housing assembly (20) from wheel assembly (11). Remove piston ring (12) and backplate (10) from the wheel assembly.5. Use tool (C), and remove snap ring (4) from housing assembly (20). Remove insert (5) and sleeve (22) from the housing assembly. Remove ring (21) from sleeve (22).6. Remove two screws (7), deflector (19), ring (24), bearing assembly (8), sleeve (9), and ring (18) from the housing assembly.7. Remove O-ring seal (6). Use tool (D) and remove snap ring (23) from the housing assembly. Remove bearing (17). Use tool (D) and remove snap ring (16) behind the bearing.8. Use tool (D) and remove snap ring (13) from the housing assembly. Remove bearing (14). Remove snap ring (15) behind the bearing with tool (D).9. Check all the parts of the turbocharger for damage. If any parts are damaged, use new parts for replacement. See Special Instruction Form No. SMHS6854 for turbocharger reconditioning. Also, see Guidelines For Reusable Parts, Form No. SEBF8018. The following steps are for the assembly of the turbocharger.10. Make sure that all the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Do not put oil on any parts of the turbocharger until after the compressor wheel has been installed. After the turbocharger has been assembled, put clean engine oil into the oil inlet of the turbocharger.
Make sure the snap rings that hold bearings (14) and (17) in position in housing assembly (20) are installed with the round edge of the outside diameter toward the bearing.
11. Install snap ring (15) with tool (D). Install bearing (14). Install snap ring (13) with tool (D).12. Install snap ring (16) behind bearing (17) with tool (D). Install bearing (17). Install snap ring (23) with tool (D).13. Install O-ring seal (6) in the housing assembly.14. Put wheel assembly (11) in position on tool (B) with the threaded portion end up. Put backplate (10) in position on the wheel assembly. Put 6V2055 High Vacuum Grease in the groove for ring (12) at assembly to one half or more of the depth of the groove all the way around.15. Install piston ring (12) in the groove in wheel assembly (11).16. Put housing assembly (20) in position on wheel assembly (11). Install ring (18) and sleeve (9) on the wheel assembly.17. Make sure the screen is in place in bearing assembly (8). Install bearing assembly (8) over the sleeve. Make sure the screen in the bearing assembly is facing down when it is installed.18. Put ring (24) in position on bearing assembly (8). Install deflector (19) with two screws (7). Put 6V2055 High Vacuum Grease in the groove of sleeve (22) to one half or more of the depth of the grooves all the way around.19. Install ring (21), in the groove, in sleeve (22). Put sleeve (22) in position in insert (5). Install the insert and sleeve as an assembly.20. Use tool (C) and install snap ring (4) to hold insert (5) on the housing assembly. 21. Put compressor wheel (2) in position in the compressor housing (25). Center the wheel in the compressor housing.22. Use a straight edge and a depth micrometer (26) and measure the distance between the wheel seating face and the compressor housing mounting face (dimension X) in four places. Find the average of the measurements. 23. Use a depth micrometer (26) to measure the distance between the face of housing assembly (20) and the surface of sleeve (22) [dimension Y].24. Use a depth micrometer (26) and measure the distance between the surface of housing assembly (20) and the compressor housing mounting face (dimension Z).25. Calculate the necessary shim thickness as follows: The shims must be of uniform thickness and free of burrs and other imperfections. The total shim thickness should be 0.13 mm to 0.41 mm (.005 to .016 in.) and consist of one or two shims.26. Install compressor wheel (2) at room temperature as follows:a. With the correct amount of shims, position wheel assembly (11) and housing assembly (20).b. Put a small amount of clean engine oil on the threads of the wheel assembly.
Do not put a side force on the shaft when the nut that holds the compressor wheel in position is tightened.
c. Install the nut that holds wheel (2)