5005966 JOHNSON Service Manual - English

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more information. If the turbocharger is worn, the complete turbocharger must be replaced.
Illustration 1 g06327337
If necessary, follow Step 2a through Step 2g to install tube assembly (31).
Install a new O-ring seal (33) (not shown) to the adapter. Ensure that the O-ring seal is correctly seated into the recess of the adapter.
Install tube assembly (31) and loosely install bolt (30) and bolt (32) to the clips on the tube assembly.
Connect tube nut (34) to the adapter hand tight.
Tighten tube nut (34) to a torque of 45 N m (33 lb ft). Use a suitable tool to hold the adapter as the tube nut is tightened.
Tighten bolt (30) and bolt (32) to a torque of 10 N m (89 lb in).
Install the fuel injection pump to fuel manifold high-pressure line. Refer to Disassembly and Assembly, "Fuel Injection Lines - Install" for the correct procedure.
Install the throttle valve. Refer to Disassembly and Assembly, "Throttle Valve - Remove and Install" for the correct procedure.
Illustration 2 g06152691
If necessary, follow Step 3a through Step 3g to install tube assembly (24).
If necessary, follow Step 3b through Step 3d to assemble tube assembly (24) and tube assembly (28).
Install hose clamp (29) to tube assembly (28). Ensure that the hose clamp is correctly orientated. Install hose (25) to the tube assembly.
Use a suitable tool to compress and slide the hose clamp onto the hose assembly.Note: Ensure that the hose clamps are correctly positioned onto the hose assembly.
Install hose clamp (29A) to tube assembly (24). Ensure that the hose clamp is correctly orientated. Install the tube assembly into hose (25) and align temporary marks.
Use a suitable tool to compress and slide the hose clamp onto the hose assembly.Note: Ensure that the hose clamp is correctly positioned onto the hose assembly.
Install a new gasket (26) (not shown) to tube assembly (28). Ensure that the gasket is correctly positioned onto the tube assembly.
Position tube assembly (24) onto the cylinder block. Install bolts (27). Tighten the bolt to a torque of 10 N m (89 lb in).
Illustration 3 g06152310
Illustration 4 g06152320
Ensure that the gasket surfaces of turbocharger (8) and exhaust manifold (21) are clean and free from wear or damage.
Install studs (22) and stud (23) to turbocharger (8). Tighten the studs to a torque of 11 N m (97 lb in).
Install a new gasket (19) (not shown). Ensure that the gasket is correctly orientated.
Install turbocharger (8) to exhaust manifold (21).
Install tube assembly (24) and gasket (18) (not shown) onto turbocharger (8). Ensure that the gasket is correctly orientated.
Install nuts (20) and Allen head bolts (17) hand tight.
Tighten nuts (20) to a torque of 21 N m (186 lb in).
Tighten nuts (20) to an additional torque of 28 N m (248 b in).
Tighten Allen head bolts (17) to a torque of 12 N m (106 lb in).
Illustration 5 g06331626
Lubricate the bearings of the turbocharger with clean engine oil through the oil inlet port in position (X). Rotate the shaft of the turbocharger to distribute the lubricant.Note: Ensure that the used O-ring has been removed from the banjo bolt (14)
Install a new O-ring seal (15) (not shown) to banjo bolt (14). Install the banjo bolt to the tube assembly (28) and install new O-ring seal (16) (not shown).
Install banjo bolt (14) to turbocharger (8). Tighten the banjo bolt to a torque of 15 N m (133 lb in).
Illustration 6 g06152295
Install a new gasket (9) (not shown) between turbocharger (8) and exhaust adapter (10). Ensure that the gasket is correctly orientated and is aligned to the bolt holes in the turbocharger.
Install bolts (11) to exhaust adapter (10). Tighten the bolts to a torque of 44 N m (32 lb ft).
Illustration 7 g06384810
Typical example
Loosely install bolts (12) to the engine cylinder head. Position the heat shield (12A) onto the bolts. Tighten the bolts hand tight.
Tighten bolts (12) to a torque of 8 N m (71 lb in)
Tighten bolts (10) to a torque of 15 N m (133 lb in)
Illustration 8 g06152286
Connect inlet tube assembly (4) to the inlet of the turbocharger.
Install breather hose assembly (1) to inlet tube assembly (4), Ensure the hose clamps (6) are correctly positioned.
Tighten the hose clamps to a torque of 4.5 N m (40 lb in). for inlet tube assembly (4). Ensure that the inlet tube assembly is correctly orientated.
Use a suitable tool to expand hose clamp (2) and slide into position on the breather hose assembly (1) . Ensure that the hose clamp is correctly positioned onto the breather hose.
Connect harness assembly (5) to wastegate actuator (3).
If a new turbocharger is installed, use the electronic service tool to perform the "Turbocharger Wastegate Actuator Replacement Reset". Refer to Troubleshooting, "Service Tool Features" for more information.
If a new