0438592 JOHNSON WATER PUMP REPAIR KIT (Includes impeller hous ing)

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Air inlet and exhaust system (1) Exhaust manifold (2) Inlet manifold and aftercooler (3) Engine cylinder (4) Air inlet (5) Turbocharger compressor wheel (6) Turbocharger turbine wheel (7) Exhaust outletClean inlet air from the air cleaner is pulled through air inlet (4) of the turbocharger by the turning of compressor wheel (5). The compressor wheel causes a compression of the air. The air then flows to the aftercooler, and then to inlet manifold (2) of the engine. When the inlet valves open, the air flows into engine cylinders (3). The air is mixed with the fuel for combustion. When the exhaust valves open, the exhaust gases go out of the engine cylinders and into exhaust manifold (1). From the exhaust manifold, the exhaust gases flow through the blades of turbine wheel (6) causing the turbine wheel and compressor wheel to turn. The exhaust gases then flow out of exhaust outlet (7) of the turbocharger.Aftercooler
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Aftercooler (typical example) (1) Air inlet pipe (2) Aftercooler (3) Water inlet pipe (4) Water outlet pipeThe aftercooler (2) cools the air that comes from the turbocharger before the air goes into the inlet manifold. The aftercooler is located toward the rear of the engine between the cylinder heads. Coolant from the water pump flows through water inlet pipe (3) into the aftercooler. The water then flows through the aftercooler core assembly through a different water outlet pipe (4) into the rear of the cylinder block. Inlet air from the compressor side of the turbocharger flows into the aftercooler through air inlet pipe (1). The air passes through the core assembly and lowers the temperature of the air to approximately 93 °C (200 °F). The cooler air goes out of the bottom of the aftercooler and into the inlet manifold. Cooler air is denser air. Dense air will help the engine burn the fuel more efficiently. This denser air gives the engine more power.Turbocharger
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Turbocharger (typical example) (1) Air inlet pipe (2) Turbocharger (3) Turbocharger support manifoldThe turbocharger (2) is mounted to the turbocharger support manifold (3). All of the exhaust gases go from the turbocharger support manifold through the turbocharger.
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Turbocharger (typical example) (4) Air inlet (5) Compressor wheel (6) Turbine wheel (7) Exhaust outlet (8) Compressor housing (9) Oil inlet port (10) Thrust collar (11) Thrust bearing (12) Turbine housing (13) Spacer (14) Air outlet (15) Oil outlet port (16) Bearing (17) Lubrication passage (18) Bearing (19) Exhaust inletThe exhaust gases enter the turbocharger and the blades of the turbocharger turbine wheel (6) are turned. Because the turbocharger turbine wheel is connected by a shaft to the turbocharger compressor wheel (5), the turbine wheel and the compressor wheel turn at high speeds. The rotation of the compressor wheel pulls clean air through the compressor housing air inlet (4). The action of the compressor wheel blades causes a compression of the inlet air. This compression allows a larger amount of air to enter the engine. With more air in the engine, the engine is able to burn more fuel. The overall effect is an increase in power.When the load on the engine increases or when a greater engine speed is desired, additional fuel is injected into the cylinders. The added fuel creates more exhaust gases, which cause the turbine wheel and the compressor wheel to turn faster. Additional air is forced into the engine as the compressor wheel turns faster. The increased flow of air allows the engine to produce more power. The engine produces more power because the engine is able to burn additional fuel with greater efficiency.The maximum rpm of the turbocharger is controlled by the following items:
Fuel setting
High idle rpm setting
Height above sea level
If the high idle rpm or the engine rating is higher than given in the Technical Marketing Information (TMI) for the height above sea level at which the engine is operated, there can be damage to engine or to turbocharger parts. Damage will result when increased heat and/or friction due to the higher engine output goes beyond the engine cooling and lubrication system's abilities.
The bearings (16) and (18) in the turbocharger use engine oil under pressure for lubrication. The oil comes in through the oil inlet port (9). The oil flows through the passages in the center section for the lubrication of the bearings. The oil flows out of the oil outlet port (15) to the engine lubrication system.Valve System Components
The valves and the valve mechanism control the flow of inlet air into the cylinders during engine operation. The valves and the valve mechanism control the flow of exhaust gases out of the cylinders during engine operation.The crankshaft gear drives the camshaft gear. The camshaft gear is in time with the crankshaft gear. The timing provides the correct relationship between the piston and the valve movement.The camshaft has two lobes for each cylinder. One lobe controls the exhaust valves. The other lobe controls the inlet valves.
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Valve system components (typical example) (1) Inlet valve bridge (2) Inlet rocker arm (3) Valve pushrod (4) Rotocoil (5) Valve spring (6) Valve guide (7) Inlet valves (8) Lifter (9) Camshaft
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Valve system components (typical example) (1) Inlet valve bridge (2) Inlet rocker arm (7) Inlet valves (10) Exhaust rocker arm (11) Exhaust valve bridge (12) Exhaust valvesThe camshaft lobes (9) turn and the lifters (8) move up and down. This movement causes the pushrods (3) to move. The pushrods move the rocker arms (2) and (10) up and down. The rocker arms move the inlet valve bridge (1) and the exhaust valve bridge (11) up and down. The bridges are attached to the cylinder head by dowels. These b