0207864 JOHNSON APPLIQUE,Rear

Sulfuric Acid Burn Hazard may cause serious personal injury or death.The exhaust gas cooler may contain a small amount of sulfuric acid. The use of fuel with sulfur levels greater than 15 ppm may increase the amount of sulfuric acid formed. The sulfuric acid may spill from the cooler during service of the engine. The sulfuric acid will burn the eyes, skin and clothing on contact. Always wear the appropriate personal protective equipment (PPE) that is noted on a material safety data sheet (MSDS) for sulfuric acid. Always follow the directions for first aid that are noted on a material safety data sheet (MSDS) for sulfuric acid.
Illustration 1 g02619576
Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.
Remove bolts (1) and bolts (10) from tube assembly (2).
Remove tube assembly (2) from exhaust cooler (12) and the cylinder head.
Remove gaskets (3) (not shown) and gasket (11) (not shown) from tube assembly (2).
Prior to and during removal of bolts (4) and bolts (16) apply releasing fluid to the bolts. Remove bolts (4) and bolts (16) from tube assembly (6).
Remove tube assembly (6) from exhaust cooler (12) and the exhaust manifold.
Remove gaskets (5) (not shown) and gasket (15) (not shown) from tube assembly (6).
Remove bolts (8) and bolts (14) from tube assembly (7).
Remove tube assembly (7) from exhaust cooler (12) and the cylinder head.
Remove gasket (9) (not shown) and gasket (13) (not shown) from tube assembly (7).
Illustration 2 g02619577
Cut cable straps (21) for wiring harness assembly (17). Ensure that all the cable straps are removed from all harness assemblies.
Slide locking tab (18) into the unlocked position. Disconnect wiring harness assembly (17) from engine wiring harness assembly (19).
Remove bolts (20) from tube assembly (23).
Remove bolt (24) from clamp on tube assembly (23).
Remove bolts (25) from tube assembly (23).
Remove tube assembly (23). Remove gasket (26) (not shown) and gasket (22) (not shown) from tube assembly (23).
Illustration 3 g02619578
Remove bolt (27) and bolts (28) from exhaust cooler (12). Note: The exhaust cooler should be supported as the bolts are removed.
Remove exhaust cooler (12) from the cylinder block. Installation Procedure
Ensure that the harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the harness assembly and the convoluting.
Note: The NRS exhaust cooler should not be disassembled or cleaned.
Install exhaust cooler (12) in the reverse order of removal.
Ensure that the exhaust cooler is clean and free from restriction. Ensure that the exhaust cooler is free from wear and damage. If necessary, replace any components that are worn or damaged.
Ensure that all tube assemblies are free from restriction and damage.
Tighten bolt (27) and bolts (28) to a torque of 22 N m (195 lb in)
Tighten bolts (20) to a torque of 9 N m (80 lb in).
Tighten bolts (25) to a torque of 18 N m (159 lb in).
Tighten bolt (24) to a torque of 22 N m (195 lb in).
Tighten bolts (10) to a torque of 18 N m (159 lb in).
Tighten bolt (2) to a torque of 22 N m (195 lb in).
Tighten bolt (14) and bolts (8) to a torque of 22 N m (195 lb in)
Tighten bolts (4) and bolts (16) to a torque of 22 N m (195 lb in).