96457 Mercruiser WASHER, FUSE TERMINAL

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 g02868256
If necessary, follow Step 2.a through Step 2.g in order to install boost pressure chamber cover (33).
Position gasket (27) (not shown) onto boost pressure chamber cover (33).
Position boost pressure chamber cover onto the engine oil cooler and install bolts (30). Tighten the bolts to a torque of 10 N m (89 lb in)
Install a new sealing washer (32) to banjo bolt (31). Install the banjo bolt assembly to hose assembly (26) and install the remaining sealing washer (32). Install hose assembly (26) to boost pressure chamber cover (33) finger tight.
Install tube assembly (26) into clip (25).
Install a new sealing washer (29) to banjo bolt (28). Install the banjo bolt assembly to hose assembly (8) and install the remaining sealing washer (28). Install hose assembly (8) to boost pressure chamber cover (33) finger tight.
Tighten banjo bolt (28) and banjo bolt (32) to a torque of 12 N m (106 lb in).
Install the alternator and mounting bracket. Refer to Disassembly and Assembly, "Alternator - Remove and Install" for the correct procedure.
Illustration 2 g02868099
Illustration 3 g02719524
Test the turbocharger actuator for correct operation. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more information. If the actuator is damaged or the actuator does not operate within the specified limits, the complete turbocharger must be replaced.
If necessary, follow Step 4 through Step 4.f in order to install tube assembly (9).
Install new O-ring seal (19) (not shown) to tube assembly (9).
Install tube assembly (9) to the cylinder block.
Install bolt (17) to tube assembly (9). Tighten the bolt to a torque of 25 N m (221 lb in).
Install O-ring seal (15) (not shown) to tube assembly (18).
Install tube assembly (18) to the oil cooler assembly. Install bolts (16) to tube assembly (18). Tighten the bolts to a torque of 25 N m (221 lb in).
Fill the coolant from the coolant system. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.
Clean the gasket surface of exhaust manifold (24). If necessary, install studs (22) to exhaust manifold (24) and turbocharger (14). Tighten the studs to a torque of 15 N m (133 lb in).
Install a new gasket (23) (not shown) to the exhaust manifold.
Position turbocharger (14) onto exhaust manifold (24) and install washers (21) and new nuts (20). Tighten the nuts to a torque of 28 N m (248 lb in). Note: Do not use the actuator rod to lift the turbocharger.
Illustration 4 g02847785
Position a new gasket (13) (not shown) onto tube assembly (9).
Position tube assembly (9) onto the turbocharger.
Install bolts (12) finger tight.
Tighten bolts (12) to a torque of 10 N m (89 lb in).
Lubricate the bearings of the turbocharger with clean engine oil through the oil inlet port. Rotate the shaft of the turbocharger in order to distribute the lubricant.
Position a new sealing washer (2) (not shown) onto banjo bolt (1). Install banjo bolt (1) onto tube assembly (11) and install remaining new sealing washer (2) to banjo bolt (1).
Position tube assembly (11) onto the cylinder block. Loosely install nut (10).
Position tube assembly (11) onto the turbocharger. Loosely install banjo bolt (1).
Tighten banjo bolt (1) to a torque of 35 N m (26 lb ft). Note: Ensure that the tube assembly does not come into contact with any other engine component.
Tighten nut (10) to a torque of 25 N m (221 lb in).
Connect hose assembly (8) to the wastegate actuator. Install hose clamp (7) to hose assembly (8). Tighten the hose clamp securely. Note: Ensure that hose clamp is correctly positioned on the hose assembly.
Connect hose assembly (4) to the turbocharger. Install hose clamp (5) to hose assembly (4). Tighten the hose clamp securely. Note: Ensure that hose clamp is correctly positioned on the hose assembly.
Connect the hose assemblies to turbocharger inlet (6) and for turbocharger outlet (3). Securely tighten the hose clamps. End By:
Install the flexible exhaust pipe to the turbocharger. Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure.