0388516 JOHNSON CYLINDER CRANKCASE ASSY.

Illustration 1 g02160475
Illustration 2 g02160476
Slide locking tab (2) into the unlocked position. Disconnect harness assembly (1) from differential pressure sensor (3).
Remove bolts (4).
Make temporary marks on differential pressure sensor (3) for installation purposes. Remove the differential pressure sensor from manifold (5).
Remove O-ring seal (6) and O-ring seal (7).
Illustration 3 g02160477
Slide locking tab (10) into the unlocked position. Disconnect harness assembly (11) from absolute pressure sensor (9).
Use a deep socket to remove absolute pressure sensor (9) from sensor manifold (5).
Remove O-ring seal (8) (not shown) from pressure sensor (9).
Illustration 4 g02160478
Illustration 5 g02160482
If necessary, follow Step 8.a through Step 8.g in order to remove manifold (5) and tube assemblies from the NOx reduction system (NRS) manifold.
Remove plastic breather tube from the crankcase breather cannister and the valve mechanism cover. Refer to Disassembly and Assembly, "Crankcase Breather- Remove" for the correct procedure.
Remove bolt (13) from tube assembly (15). Remove bolt (14) from clip for the tube assembly. Loosen hose clamp (16) from the hose for tube assembly (15).
Remove tube assembly (15) from manifold (5) and the NRS manifold. Remove O-ring seal (12) (not shown).
Remove bolt (17) from tube assembly (19). Remove bolt (20) from clip for the tube assembly. Loosen hose clamp (25) from hose for tube assembly (19).
Remove tube assembly (19) from manifold (5) and the NRS manifold. Remove O-ring seal (18) (not shown).
If necessary, remove connection (21) and connection (25) from the NRS manifold.
Cut cable strap (23) from harness assemblies. Remove bolts (24) from manifold (5). Remove manifold (5) from the inlet elbow. Installation Procedure
Ensure that wiring harness are correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged. Ensure that all tube assemblies are clean and free from restriction.
Illustration 6 g02160478
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If necessary, follow Step 2.a through Step 2.j in order to install manifold (5) and tube assemblies to the NOx reduction system (NRS) manifold.
If necessary, install connection (21) and connection (22) NRS manifold. Tighten connections to a torque of 9 N m (80 lb in).
Position manifold (5) onto the inlet elbow. Install bolts (24). Tighten the bolts to a torque of 22 N m (195 lb in).
Install a new O-ring seal (10) (not shown) onto tube assembly (19). Install tube assembly (19) into manifold (5) and install bolt (17).
Install hose for tube assembly (19) onto connection (25). Install bolt (20) for the clip for tube assembly (19).
Tighten bolt (20) and bolt (17) to a torque of 22 N m (195 lb in). Securely tighten hose clamp (25).
Install a new O-ring seal (12) (not shown) onto tube assembly (15). Install tube assembly (15) into manifold (5) and install bolt (13).
Install hose for tube assembly (15) onto connection (21). Install bolt (14) for the clip for tube assembly (15).
Tighten bolt (13) and bolt (14) to a torque of 22 N m (195 lb in). Securely tighten hose clamp (16).
Install plastic breather tube to the crankcase breather cannister and the valve mechanism cover. Refer to Disassembly and Assembly, "Crankcase Breather- Install" for the correct procedure.
Install a new cable strap (23) to harness assemblies. Note: Ensure that cable straps meet the Original Equipment Manufactures (OEM) specification.
Illustration 8 g02160477
Install a new O-ring seal (8) (not shown) to pressure sensor (9). Note: Do not lubricate the O-ring seal.
Use a deep socket to install absolute pressure sensor (9) to manifold (5). Tighten pressure sensor (9) to a torque of 10 N m (89 lb in).
Connect harness assembly (11) to absolute pressure sensor (8). Slide locking tab (10) into the locked position.
Illustration 9 g02160475
Illustration 10 g02160476