40001 1 Mercury SCREW, DETENT SPRING AND PLATE

The turbocharger does not have to be removed from the engine in order to remove the wastegate.1. Remove two clamps (1) and hose (2). 2. Remove retainer (4) and two nuts (3). 3. Remove three mounting bolts (6) and bracket (5).Disassemble Turbocharger (Schweitzer S4A)
Start By:a. remove turbocharger 1. Install the turbocharger on tool (A) as shown.2. Put alignment marks on three housings of the turbocharger for correct alignment during assembly. Loosen clamp (2), and remove the clamp and housing (1) from housing assembly (3). 3. Loosen clamp (4), and remove housing assembly (3) from housing (5). 4. Put the cartridge group in position in tool (B) as shown.
When the nut is loosened, do not put a side force on the shaft. This can result in a bent shaft.
5. Use a 5S9566 Sliding T-Wrench and a universal socket (6) to remove the nut that holds the compressor wheel to the wheel assembly.6. Remove compressor wheel (7) and the shims from wheel assembly (8).7. Remove housing assembly (3). 8. Remove ring (9) and backplate (10). 9. Use tool (C), and remove snap ring (11). 10. Remove insert (12) and sleeve (13). 11. Remove ring (14). 12. Remove two screws (15) and deflector (16). 13. Remove ring (18) and bearing assembly (17). 14. Remove sleeve (19) and ring (20). 15. Remove O-ring seal (23). Use tool (D), and remove snap ring (22).16. Remove bearing (21). Remove the snap ring behind the bearing with tool (D). 17. Use tool (D), and remove snap ring (25). Remove bearing (24). Remove the snap ring behind the bearing with tool (D).18. Check all the parts of the turbocharger for damage. If the parts are damaged, use new parts for replacement. See Special Instruction, Form No. SMHS6854, for Turbocharger Reconditioning. Also, see Guidelines For Reusable Parts, Form No. SEBF8018.Assemble Turbocharger (Schweitzer S4A)
1. Make sure that all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Do not put oil on any parts of the turbocharger until after the compressor wheel has been installed. After the turbocharger has been assembled, pour clean engine oil into the oil inlet of the turbocharger.
Make sure that the snap rings that hold bearings (24) and (21) in position in housing assembly (3) are installed with the round edge of the outside diameter toward the bearing.
2. Install the snap ring behind bearing (24) with tool (D). Install bearing (24).3. Use tool (D), and install snap ring (25). 4. Install the snap ring behind bearing (21) with tool (D). Install bearing (21).5. Use tool (D), and install snap ring (22). 6. Put wheel assembly (8) in position on tool (B) as shown. Put backplate (10) in position on the wheel assembly. Put 6V2055 High Vacuum Grease in the groove for seal ring (9) at assembly to one half or more of the depth of the groove all the way around.7. Install ring (9) in the groove in wheel assembly (8). 8. Install housing assembly (3) on wheel assembly (8). 9. Install ring (20) and sleeve (13). 10. Make sure the screen is in place in bearing assembly (17). 11. Install bearing assembly (17) over the sleeve. Make sure the screen in the bearing assembly is facing down when it is installed.12. Put ring (18) in position on bearing assembly (17). 13. Install deflector (16) and two screws (15). Tighten screws (15) to a torque of 2.25 .25 N m (20 2 lb in). Put 6V2055 High Vacuum Grease in the groove of sleeve (13) to one half or more of the depth of the grooves all the way around.14. Install ring (14) in the groove in sleeve (13). 15. Put sleeve (13) in position in insert (12). Install the insert and sleeve (13) as an assembly. 16. Use tool (C), and install snap ring (11). 17. Put wheel (7) in position in compressor housing (1). Center the wheel in the compressor housing.18. Use a straight edge and a depth micrometer (26) and measure the distance between the wheel seating face and the compressor housing mounting face (dimension X) in four places. Find the average of the measurements. 19. Use a depth micrometer (26) to measure the distance between the surface of housing assembly (3) and the surface of sleeve (13) (dimension Y).20. Use a depth micrometer (26), and measure the distance between the surface of housing assembly (8) and the compressor housing mounting face (dimension Z).21. Calculate the necessary shim thickness as follows: Dimension Z- Dimension Y- Dimension X + 0.23 to 0.28 mm (.009 to .011 in)= Correct Shim Thickness The shims must be of uniform thickness and free of burrs and other imperfections. The total shim thickness should be 0.13 mm to 0.41 mm (.005 to .016 in) and consist of one or two shims.22. Install wheel (7) at room temperature as follows:a. Put the correct amount of shims and wheel (7) in position on the wheel assembly.b. Put a small amount of clean engine oil on the threads of the wheel assembly.
Do not put a side force on the shaft when the nut that holds the compressor wheel in position is tightened.
c. Install the nut that holds wheel (7) in place. Tighten the nut to a torque of 14 to 17 N m (125 to 150 lb in).d. Remove the nut, and put 6V1541 Quick Cure Primer on the threads of the wheel assembly.e. Put 9S3265 Retaining Compound on the threads of the wheel assembly, and install the nut. Tighten the nut to a torque of 4 N m (35 lb in).f. Tighten the nut an additional 90°. 23. Install housing (5) on tool (A) as shown.24. Put housing assembly (3) in its original position in housing (5), and install clamp. Tighten clamp (4) to a torque of 14 3 N