808503 Mercruiser ELECTRICAL CONNECTOR KIT

1. Drain the coolant from the cooling system.2. Loosen the clamps that hold hoses (1) and slide the hoses away from the turbochargers. 3. Loosen the clamps that hold elbows (2) in position and remove the elbows.4. Remove water line (4). Remove shield assemblies (3). 5. Loosen clamps (6) and remove pipe assembly and elbow assembly (5) and (7). 6. Remove oil supply lines (10) from each turbocharger. Remove water lines (8) from each turbocharger.7. Disconnect two water lines from the bottom of each turbocharger.8. Disconnect oil drain lines (12) from each turbocharger.9. Remove the bolts that hold elbows (13) to the aftercooler.10. Fasten a hoist to turbocharger (11). Remove the bolts that hold the turbocharger to the exhaust manifold, and remove the turbocharger and elbow (13) as an assembly. The weight of the turbocharger and elbows is 51 kg (113 lb) each.11. If necessary, remove elbows (9) and (13) from each turbocharger (11). The following steps are for installation of the turbochargers.12. If elbows (9) and (13) 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.13. Put new gaskets in position on the exhaust manifold and the aftercooler housing.14. Put turbocharger (11) and the elbows in position on the engine.15. 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 55 7 N m (41 5 lb ft).16. Install the bolts that hold elbows (13) to the aftercooler housing.17. 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.18. Put the gaskets and oil drain lines (12) 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.19. 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 (10) in position on the turbocharger. Install the bolts.20. Put pipe and elbow assemblies (5) and (7) in position. Tighten clamp (6) to a torque of 15 3 N m (11 2 lb ft).21. Install shield assemblies (3). Apply 5P3931 Anti-Seize Compound to the threads of the bolts.22. Install water line (4).23. Put elbows (2) in position and tighten the clamps.24. Put hoses (1) in position on the turbochargers and install and tighten the clamps.25. Fill the cooling system with coolant to the correct level. See the Maintenance Manual.Disassemble Turbocharger
Start By:a. remove turbocharger 1. Put the turbocharger in position on tool group (A) as shown.2. Put marks on the housings of the turbocharger for correct installation and alignment at assembly.3. Loosen clamp (2) and remove compressor housing (3) and clamp (2) from the cartridge assembly. 4. Loosen clamp (4) and remove cartridge assembly (5) from turbine housing (6).
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 tooling (B). Use a universal joint and socket of the correct size to remove the nut that holds compressor wheel (7) on the turbine shaft 6. Use a press and push the turbine shaft out of compressor wheel (7) and the cartridge housing. Remove compressor wheel (7) from the cartridge housing. 7. Remove shroud (9) from turbine shaft (8). 8. Remove seal ring (10) from turbine shaft (8). 9. Bend the tabs of the locks from bolts (11) and remove the bolts.10. Remove backplate assembly (12) 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. 11. Push spacer (13) out of the bore in backplate (12). 12. Remove seal rings (14) from spacer (13). 13. Remove seal (15) from the cartridge housing. 14. Remove thrust collar (16) from the cartridge housing. 15. Remove thrust bearing (17) from the cartridge housing. If the bearings are to be used again, put identification on them, as to their location, for correct assembly.16. Remove bearing (18) from the cartridge housing. 17. Remove washer (19) from the cartridge housing. 18. Remove snap rings (20) and (21) with tooling (C). 19. Remove bearing (22) from the cartridge housing. 20. Remove washer (23) from the cartridge housing. 21. Remove snap ring (24) from the cartridge housing with tooling (C). 22. Turn the cartridge housing over. Remove plates (25) from the cartridge housing.Assemble Turbocharger
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. 3. Install plates (25) on the cartridge housing. Turn the cartridge housing over. Make sure the round edge on the outside diameter of the snap ring is toward the bearing when the snap rings are installed.4. Install snap ring (24) in the turbine end of the cartridge housing with tool (A). Install washer (23) and bearing (22). 5. Install snap ring (21) in the cartridge housing with tool (A) to hold the washer and bearing in place. 6. Install snap ring (20) in the cartridge housing with tool (A).7. Install washer (19) and bearing (18) in the cartridge housing until washer (19) makes contact with snap ring (20). 8. Install thrust bearing (17) over the dowels in the cartridge housing. Make sure the grooves in bearing (17) are toward the outside as shown. 9. Put thrust collar (16) in position on the thrust bearing with the counterbore for the spacer up. 10. Install seal ring (15) in the groove of the cartridge housing. 11. Install seal rings (14) on spacer (13) so the gaps