0388862 JOHNSON CARB ASSY., Upper, 115 HP

Table 1
Required Tools
Tool Part Number Part Description Qty
A 473-2944 Capping Kit 1
B 438-6765 Plug 3
At temperatures lower than −15° C (5° F), care should be taken when removing the Diesel Exhaust Fluid (DEF) line connectors that are attached to the tank, pump, and injector. To limit possible damage to the DEF line connectors, carefully apply heat to the area of the DEF line connectors.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Turn the battery disconnect switch to the OFF position.
Illustration 1 g03387678
Typical example
Disconnect diesel exhaust fluid line (1) from DEF injector (3).
Use Tooling (A) to plug diesel exhaust fluid line (1).
Use Tooling (A) to cap connection (2) on DEF injector (3).
Illustration 2 g03388836
Typical example
Disconnect harness assembly (4). Use Tooling (B) to plug the harness assembly connection on the Pump Electronics Tank Unit (PETU).
Cap harness assembly (4).
Disconnect diesel exhaust fluid line (1) from connector (6) from Pump Electronics Tank Unit (PETU) (5).
Use Tooling (A) to cap diesel exhaust fluid line (1).
Use Tooling (A) to cap connection (6) on PETU (5).
Illustration 3 g03418500
Cut cable straps (7) and cable straps (11) from diesel exhaust fluid line (12).Note: Note position of all cable straps for installation purposes.
Disconnect harness assembly (9) from the PETU harness assembly. Use Tooling (B) to plug the harness assembly connection on the PETU.
Cap harness assembly (9).
Remove bolt (10) from the clip.
Disconnect diesel exhaust fluid line (12) from manifold DEF heater (13) and the diesel emission fluid pump.
Use Tooling (A) to plug diesel exhaust fluid line (12). Use Tooling (A) to cap manifold DEF heater (13) and the diesel emission fluid pump.
Cut cable strap (14) and cable straps (16) from diesel exhaust fluid line (18).Note: Note position of all cable straps for installation purposes.
Remove bolt (15) and bolt (17) from the clips.
Disconnect harness assembly (8) from the PETU harness assembly. Use Tooling (B) to plug the harness assembly connection on the PETU.
Cap harness assembly (8).
Disconnect diesel exhaust fluid line (18) from manifold DEF heater (13) and the diesel emission fluid pump.
Use Tooling (A) to plug diesel exhaust fluid line (18). Use Tooling (A) to cap manifold DEF heater (13) and the diesel emission fluid pump.Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
C - De-ionized Water 1
Distilled Water
Diesel Exhaust Fluid (DEF) Note: Use de-ionized water, distilled water, or Diesel Exhaust Fluid (DEF) to lubricate the O-ring seals of the connections of the diesel exhaust fluid lines before installation of the diesel exhaust fluid lines.If DEF has been used to lubricate the O-ring seals of the connections of the diesel exhaust fluid lines. The excess DEF must be cleaned from the connections of the diesel exhaust fluid lines.
Ensure that the diesel exhaust fluid lines are clean, free from restriction, and free from wear or damage. If necessary, replace the diesel exhaust fluid lines as an assembly.
Illustration 4 g03418500
Remove plugs from diesel exhaust fluid line (18). Remove caps from manifold DEF heater (13) and the diesel emission fluid pump.
Use Tooling (C) to lubricate the O-ring seals of the connections of diesel exhaust fluid line (12). Connect the diesel exhaust fluid line to manifold DEF heater (13) and the diesel emission fluid pump.Note: If DEF has been used to lubricate the O-ring seals of the connections of the diesel exhaust fluid lines. The excess DEF must be cleaned from the connections of the diesel exhaust fluid lines.
Remove cap from harness assembly (9).
Remove the plug from the connection for harness assembly (9) on the PETU.
Connect harness assembly (9) to the harness connection on the PETU.
Install bolt (15) and bolt (17) to the clips. Tighten the bolts to a torque of 9 N m (80 lb in).
Install a new cable strap (14) and new cable straps (16) to diesel exhaust fluid line (18). Ensure that all the cable straps are correctly positioned.Note: Ensure that the cable straps meet the Original Equipment Manufacture (OEM) specifications.
Remove cap from harness assembly (8).
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