0341502 JOHNSON SEAL, Cover

1. Position gasket (10) to the exhaust manifold.2. Position turbocharger (6) to the exhaust system.3. Apply 5P-3931 Anti-Seize Compound on bolts (12). Install bolts (12) that hold the turbocharger to the exhaust manifold. Tighten bolts (12) to a torque of 55 5 N m (40 4 lb ft).4. Install precleaner tube (7) and clamp (3) to turbocharger (6). Tighten clamp (3).5. Install the dust ejector hose and clamp (1) on turbocharger (6). Tighten clamp (1).6. Position oil supply tube assembly (9) to the turbocharger and the engine. Install bolts (4) and the fitting on the opposite end of the oil line.7. Position oil return tube assembly (11) in the engine block and on the turbocharger. Install bolts (8) and washers.Disassemble Turbocharger
Start By:a. remove turbocharger 1. Install turbocharger on Tool Group (A). Put marks on the three housings of the turbocharger for correct installation and alignment at assembly.2. Remove bolts (1) and lock washers. Remove four plates and compressor housing (2). 3. Remove two locks, two plates and four bolts (3) that hold the cartridge housing to the turbine housing. Remove cartridge housing (4).
When the nut is loosened, do not put a side force on the shaft. The shaft can bend.
4. Put the cartridge assembly on Tool (B) as shown. Use Tool (C) and the correct size socket to remove the nut that holds compressor wheel (5) on the shaft.5. Hold the cartridge assembly down in Tool (B) and lift and turn the compressor wheel (5) at the same time to remove it from the shaft. 6. Remove cartridge assembly (6) from the shaft. 7. Remove bearing (7) and ring (8) from the shaft. 8. Remove ring (9) from the housing assembly with Tool (B). 9. Remove the insert, sleeve and deflector from the housing assembly as a unit. Use two screwdrivers to remove the unit. 10. Remove O-ring seal (14) from insert (13). Remove sleeve (10) from insert (13) and deflector (11). Remove ring (12) from sleeve (10). 11. Remove bearing (15) from the housing assembly. 12. Turn the housing assembly over. Remove shroud (16) and the gasket from the housing assembly.Assemble Turbocharger
1. Make sure that all of the oil passages in the cartridge housing assembly are clean and free of dirt and foreign material. Put clean oil on all the parts of the cartridge assembly.2. Put shaft (17) in position in Tool (A). Install ring (8) and bearing (7) in the shaft as shown. 3. Put shroud (16) in position on the shaft as shown. 4. Put gasket (18) in position on the shroud. Install cartridge housing (4) over the shaft. 5. Install bearing (15) in housing assembly (4). Make sure the bronze side of the bearing is facing up. 6. Put deflector (11) in position over sleeve (10).7. Install ring (12) in the groove on the sleeve. Push the sleeve in insert (13). Install O-ring seal (14) on the insert. 8. Install the insert, deflector and sleeve as a unit in the housing assembly as shown. 9. Install ring (9) in the groove in the housing assembly with Tool (B). 10. Put compressor wheel (5) in position on the shaft.
Do not put a side force on the shaft when the nut that holds the compressor wheel in position is tightened. The shaft can bend.
11. Install the nut that holds the compressor wheel in position. Tighten the nut to a torque of 18.7 1.7 N m (165 15 lb in). 12. Put turbine housing (19) in position on Tool (C).13. Put cartridge housing (4) in position in the housing. Make sure the mark on cartridge assembly (4) is in alignment with the mark on the housing.14. Put 5P-3931 Anti-Seize Compound on the threads of the bolts that hold cartridge housing (4) to turbine housing (19). Install the two locks, two plates and four bolts that hold cartridge housing (4) to turbine housing (19). Tighten the bolts to a torque of 15 to 17 N m (11 to 12 lb ft).15. Bend the locks over the bolts. 16. Put compressor housing (2) in position on the cartridge housing. Make sure the mark on the housing is in alignment with mark on the cartridge housing.17. Put 5P-3931 Anti-Seize Compound on the threads of the bolts that hold compressor housing (2) to cartridge housing (4). Install the four plates and eight bolts and lock washers that hold compressor housing (2) in position. Tighten the eight bolts to a torque of 6.8 N m (60 lb in).End By:a. install turbocharger