0323692 JOHNSON WASHER, Thrust

1. Drain the coolant from the cooling system.2. Loosen the clamps that hold tube assemblies (3) and (4) and the elbows to the turbocharger and air cleaners. Remove the tube assemblies and elbows as a unit.3. Fasten a hoist to pipe assembly (1). Loosen the clamps that hold the pipe assembly to the turbocharger and the muffler assembly. Remove pipe assembly (1). The weight of the pipe assembly is 28 kg (62 lb.).4. Fasten a hoist to pipe assembly (2). Loosen the clamp that holds the pipe assembly to the turbocharger.5. Remove the bolts that hold pipe assembly (2) to the elbow. Remove the pipe assembly. The weight of the pipe assembly is 28 kg (62 lb.). 6. Remove three shield assemblies (5) from each turbocharger.7. Remove oil supply lines (6) from each turbocharger.8. Disconnect tube assemblies (8) from the turbochargers. Remove the tube assemblies from the engine.9. Disconnect two water lines from the bottom of each turbocharger.10. Disconnect oil drain lines (9) from each turbocharger.11. Remove the bolts that hold elbows (11) to the aftercooler.12. Fasten a hoist to turbocharger (7). Remove the bolts that hold the turbocharger to the exhaust manifold, and remove the turbocharger and elbow (11) as an assembly. The weight of the turbocharger and elbows is 32 kg (71 lb.).13. If necessary, remove elbows (10) and (11) from turbocharger (7). The following steps are for installation of the turbochargers.14. If elbows (10) and (11) were removed from the turbocharger, make sure the O-ring seals are in position on the elbows. Put clean engine oil on the O-ring seals, and install the elbows on the turbocharger.15. Put new gaskets in position on the exhaust manifold and the aftercooler housing.16. Put turbocharger (7) and the elbows in position on the engine.17. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold the turbocharger. Install the bolts, and tighten them to a torque of 54 5 N m (40 4 lb.ft.).18. Install the bolts that hold elbows (11) to the aftercooler housing.19. Put the gaskets and water lines in position on the bottom of each turbocharger. Put 5P3931 Anti-Seize Compound on the threads of the bolts. Install the bolts to hold the water lines in place on the turbochargers.20. Put the gaskets and oil drain lines (9) in position on the turbochargers. Put 5P3931 Anti-Seize Compound on the thread of the bolts. Install the bolts to hold the oil drain lines in place.21. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold the oil supply lines in place. Put the gaskets and oil supply lines (6) in position on the turbocharger. Install the bolts.22. Install tube assemblies (8).23. Fasten a hoist to pipe assembly (2). Put the pipe assembly in position, and install the bolts that hold it to the elbow.24. Tighten the clamp that holds the pipe assembly to the turbocharger.25. Fasten a hoist to pipe assembly (1). Put the pipe assembly in position, and tighten the clamps that hold the pipe assembly to the muffler assembly and turbocharger.26. Put tube assemblies (3) and (4) and the elbows in position on the turbochargers and air cleaners. Tighten the clamps that hold them in place.27. Fill the cooling system with coolant to the correct level. See the Maintenance Manual.Disassemble Turbochargers
Start By:a. remove turbochargers 1. Put the turbocharger in position on tool group (A) as shown. Put alignment marks on the three housings of the turbocharger for correct installation and alignment at assembly.2. Loosen clamp (2), and remove compressor housing (1) and the clamp from the cartridge assembly. 3. Bend locks (4) from the bolts. Remove the bolts, locks (4) and the clamps that hold cartridge housing (3) in turbine housing (5).4. Remove cartridge housing (3) from turbine housing (5).
To prevent a bent shaft, do not put a side force on the turbine shaft when the compressor wheel nut is loosened.
5. Put the end of the turbine shaft in tool (B). Use a universal joint and socket of the correct size to remove the nut that holds compressor wheel (6) on the turbine shaft. 6. Use a press, and push the turbine shaft out of compressor wheel (6) and the cartridge housing. Remove compressor wheel (6) from the cartridge housing. 7. Remove seal ring (8) and shroud (9) from turbine shaft (7). 8. Bend the tabs of the locks from bolts (10), and remove the bolts.9. Remove backplate assembly (11) from the cartridge housing. Make a note of the position of the oil holes in the backplate assembly and cartridge housing for correct alignment at assembly. 10. From the opposite side of backplate (11) that is shown, push spacer (12) out of its bore. 11. Remove seal rings (13) from spacer (12). 12. Remove thrust collar (14) and seal ring (15) from the cartridge housing. 13. Remove thrust bearing (16) from the cartridge housing. If the bearings are to be used again, put identification marks on them as to their location for correct assembly. 14. Remove bearing (17) from the cartridge housing. 15. Remove washer (18) from the cartridge housing. 16. Use tool (C), and remove snap rings (19) and (20) from the cartridge housing. 17. Remove bearing (21) and washer (22) from the cartridge housing. 18. If necessary, use tool (C) and compress the end snap ring, and push it out of the bearing bore toward the compressor end of the cartridge housing to remove it.Assemble Turbochargers
1. Make sure all of the oil passages in the turbocharger cartridge housing, backplate assembly and bearings are clean and free of dirt and foreign material.2. Put clean engine oil on all parts of the cartridge at assembly. Make sure the round edge on the outside diameter of the snap rings are toward the bearings when the snap rings are installed.3. Use tool (A), and install snap ring (1) in the turbine end of the cartridge housing.4. Install washer (2) and bearing (3). Use tool (A) to install snap ring (4) to hold