0329121 JOHNSON APPLIQUE, Front handle

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.
Note: Plug and cap all open ports.
Illustration 1 g06476583
Follow Step 1a through Step 1k to remove Nitrogen oxide Reduction System (NRS) cooler (4) coolant hoses.
Make temporary marks on coolant hoses and clamps for installation purposes only.
Loosen hose clamp (1). Position the hose clamp away from connection (14).
Loosen hose clamp (3). Position the hose clamp away from NRS cooler assembly (4).
Remove hose (2) from connection (14) and NRS cooler (4).
Use a suitable tool, to compress hose clamp (12). Position the hose clamp away from water pump (13).
Use a suitable tool, to compress hose clamp (10). Position the hose clamp away from the water temperature regulator housing.
Remove hose (11) from water pump (13) and the water temperature regulator housing.
Loosen hose clamp (8). Position the hose clamp away from connection (9).
Loosen hose clamp (5). Position the hose clamp away from Exhaust Gas Regulator (EGR) valve (7).
Remove hose (6) from EGR valve (7) and connection (9).
If necessary, remove connection (9) (not shown) and connection (14).
Illustration 2 g06453824
Support pipe (20). Remove bolts (15) and bolts (19). Remove gasket (16) (not shown) and gasket (18) (not shown) from the pipe.Note: Discard the gaskets.
Disconnect harness assembly (17) from EGR valve (7). Position the harness assembly away from the EGR valve.
Illustration 3 g06476590
Remove bolt (17A) from NRS cooler (4).
Illustration 4 g06453841
Support NRS cooler assembly (4). Remove bolts (21) and bolts (22).
Remove NRS cooler assembly (4) from exhaust manifold (21A). Discard gasket (23) (not shown).
Illustration 5 g06476591
If necessary, follow step 7a through step 7d to disassemble the exhaust cooler (4).
Place the exhaust cooler assembly in a suitable support.
Remove bolts (24).
Remove exhaust cooler (4) from EGR valve (7).
Discard gasket (25) (not shown) and O-ring seal (26).Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Anti-Seize Compound 1
B - Loctite 575 1
C - International Products P-80 Emulsion 1
Check all components for wear and damage. If necessary, replace any components that are worn or damaged.
Ensure that the exhaust cooler (NRS) assembly is free from restriction and external damage. Ensure that the exhaust cooler (NRS) assembly and tube assemblies are free from wear and damage. Refer to Systems Operation Testing and Adjusting, "Exhaust Cooler (NRS) - Test" for the correct inspection procedure.Note: Cleaning of the internal core of the exhaust cooler (NRS) should not be carried out.
Illustration 6 g06476592
If necessary, follow step 3a through step 3e to assemble the exhaust cooler (4).
Place EGR valve (7) in a suitable support.
Install new O-ring seal in Position (Y) in the EGR valve. Using Tooling (C), apply a small amount to the new O-ring seal.
Position new gasket (25) in Position (X) on EGR valve (7).
Install exhaust cooler to EGR valve (7). Install bolts (24) finger tight.
Tighten bolts (24) to a torque of 22 N m (195 lb in)
Illustration 7 g06453841
Clean the gasket surfaces of NRS cooler assembly (4), EGR valve (7), and exhaust manifold (21A).
Apply Tooling (A) to the thread