0389204 JOHNSON CUP AND GUIDE ASSY

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Bellows Protector 1
Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.
Do not strike any part of the assembly of the Diesel Particulate Filter (DPF). Do not allow any object to contact the internal element of the DPF. If the internal element of the DPF becomes damaged, the assembly must be replaced.
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged. Refer to Disassembly and Assembly, "Inspection of Parts" for the correct procedures.
If the flexible exhaust pipe was removed as an assembly, refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct installation procedure.
Illustration 1 g03372061
Illustration 2 g03372062
If necessary, install the temperature sensors (3) and temperature sensor (9) into the DPF. Refer to Disassembly and Assembly, "Temperature Sensor (DPF) - Remove and Install" for the correct procedure.
Position a new V-band clamp onto flexible exhaust pipe (12).
Attach a suitable lifting device to the assembly of the Diesel Particulate Filter (DPF) (4). The weight of the DPF is approximately 15 kg (33 lb).
Use the suitable lifting device in order to install the DPF to mounting bracket (10). Ensure that the flexible exhaust pipe is correctly seated onto the turbocharger and DPF with the alignment pin (not shown) fully engaged. Note: Ensure that the exhaust gases flow in the direction of temporary mark.
Remove the suitable lifting device from the assembly of the DPF.
Position clamps (5) onto DPF (4). Loosely install bolts (8).
Loosely install the Original Equipment Manufacturer's (OEM) exhaust pipe assembly to outlet section (6) of the DPF.
Align the temporary alignment marks on DPF (4) and clamps (5) in Positions (A), (B), (C) and (D). Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress.
If a new DPF is being installed, the DPF must be aligned using flexible exhaust pipe (12) as the reference point. Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress.
Position the V-band clamp onto the DPF. Tighten the flexible exhaust pipe clamp. Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure.
Tighten the OEM exhaust pipe assembly to the outlet section of the DPF. Refer to the OEM for the correct procedure.
Ensure that the DPF is installed in the original position and all of the temporary alignment marks are aligned. Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress.
Tighten bolts (8) evenly in three stages. Tighten bolts (8) to an initial torque of 8 N m (71 lb in)Tighten bolts (8) to a secondary torque of 16 N m (141.6 lb in)Tighten bolts (8) to a final torque of 25 N m (221 lb in).
If necessary, remove Tooling (A) from flexible exhaust pipe (12). Note: Do not start the engine with the bellows protector in place.
Connect the wiring harness assembly to connection (1) on temperature sensor (2).
Connect the wiring harness assembly to connection (11) on temperature sensor (3).
Connect the pressure sensor tube assembly (9) to the DPF. Tighten the connection to a torque of 30 N m (265 lb in).
Connect the pressure sensor tube assembly (7) to the DPF. Tighten the connection to a torque of 30 N m (265 lb in). End By:
If the DPF has had an ash service, it will be necessary to use the electronic service tool in order to perform the "DPF Ash Cleaning" procedure.
If the DPF required replacing and a new DPF has been installed, it will be necessary to use the electronic service tool in order to perform the "DPF Replacement Reset" procedure.