5033968 JOHNSON *WASHER (T:2.1mm)

Table 1
Required Tools
Tool Part Number Part Description Qty
A 370-4653 Counterweight Tool 1
B 4C-5597 Anti-Seize Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g03461476
Ensure that turbocharger (3) is clean and free from damage. Inspect the turbocharger for wear. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If any part of the turbocharger is worn or damaged, the complete turbocharger must be replaced.
Test wastegate actuator (25) for correct operation. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If any part of the wastegate actuator is worn or damaged, the complete turbocharger must be replaced.
Illustration 2 g03461477
Clean the gasket surface of exhaust manifold (21). If necessary, install studs (24) to turbocharger (3). Tighten the studs to a torque of 18 N m (160 lb in).
Install a new gasket (23) to studs (24).
Position turbocharger (3) onto the exhaust manifold and install nuts (22) finger tight. The nuts (22) should not constrain the turbocharger and prevent Tooling (A) from correctly positioning the turbocharger onto the exhaust manifold.
Use Tooling (A) to align turbocharger (3). Note: Ensure that the turbocharger is correctly oriented.
Illustration 3 g03459359
Turbocharger tightening sequence viewed from the exhaust manifold.
Tighten nuts (22) in the sequence shown in Illustration 3 to a torque of 44 N m (32 lb ft).
Remove Tooling (A) from turbocharger (3).
Illustration 4 g03461478
Illustration 5 g03461479
Remove plugs and caps from tube assemblies. Ensure that tube assembly (20) and tube assembly (16) are clean and free from damage. Replace any damaged components.
Position a new gasket (18) (not shown) onto tube assembly (20).
Install bolts (19) to tube assembly (20). Tighten the bolt to a torque of 22 N m (195 lb in).
Remove the plug from oil inlet port (26). Lubricate the turbocharger bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor several times in order to lubricate the bearings.
Install a new sealing washer (17) to banjo bolt (15). Install the banjo bolt to tube assembly (16). Install the remaining new sealing washer (17) to banjo bolt (15).
Position tube assembly (16) onto turbocharger (3). Tighten the banjo bolt to a torque of 20 N m (177 lb in).
Illustration 6 g03461480
Use Tooling (B) to lubricate the allen head bolt for V-band clamp (4). Position V-band clamp (4) onto air duct (14).
Position hose assembly (10) and air duct (14) onto the outlet of turbocharger (3) and the turbocharger. Ensure that V-band clamp (4) is correctly seated on the air duct (14) and turbocharger (3).
Tighten the allen head bolt for V-band clamp (4) to a torque of 12 N m (106 lb in).
Tighten hose clamps (9) to a torque of 6 N m (53 lb in).
Use Tooling (B) to lubricate the allen head bolt for V-band clamp (8). Position V-band clamp (8) onto the turbocharger.
Use Tooling (B) to lubricate the allen head bolt for V-band clamp (2). Position V-band clamp (2) onto elbow (1).
Position elbow (1) onto the turbocharger and turbocharger (3).
Tighten allen head bolt for V-band clamp (2) and allen head bolt for V-band clamp (8) finger tight. Ensure that the V-band clamps are seated correctly onto the turbochargers.
Tighten allen head bolt for V-band clamp (2) and allen head bolt for V-band clamp (8) to a torque of 12 N m (106 lb in).
Connect hose assembly (6) (not shown) to the wastegate actuator. Slide clip (3) along the hose assembly ensure that the clip is correctly positioned.
Connect hose assembly (14) to turbocharger (3). Slide clip (13) along the hose assembly ensure that the clip is correctly positioned.
Install bolt (7) (not shown) to the clip for the tube assembly. Tighten the bolt to a torque of 22 N m (195 lb in).
Connect hose assembly to air outlet (11) to turbocharger (3). Tighten the hose clamps securely.