0394283 JOHNSON CYLINDER C'CASE ASSY, 90

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.
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.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Illustration 1 g02173073
If necessary, follow Step 2.a through Step 2.d in order to install bracket (29).
Position bracket (29) onto cylinder head (30).
Install bolts (28) hand tight. Ensure that rubber sleeve (32) is correctly positioned into recess of bracket (29).
Tighten bolts (28) to a torque of 22 N m (195 lb in).
Install new cable straps (31). Note: Ensure that the cable straps meet the Original Equipment Manufacturers (OEM) specification.
Illustration 2 g02169940
Illustration 3 g02169941
Position a new gasket (15) onto inlet air control assembly (6). Ensure gasket (15) is correctly installed into locating Pins (A).
Loosen bolts (34) for bracket (33).
Tighten bolts (34) for bracket (33) to a torque of 44 N m (32 lb ft).
Illustration 4 g02169794
Illustration 5 g02351557
Illustration 6 g02169941
Position inlet air control assembly (6) onto bracket. Note: Ensure that the inlet air control assembly is correctly installed onto hose assembly for the inlet elbow.
Install bolts (25) and bolts (14) hand tight.
Tighten bolts (25) to a torque of 22 N m (195 lb in).
Tighten bolts (14) to a torque of 22 N m (195 lb in).
Connect temperature sensor (16) to the inlet air control assembly. Refer to Disassembly and Assembly, "Temperature Sensor (Cooled Exhaust Gas) - Remove and Install" for the correct procedure.
Install a new sealing washer (21) (not shown) to banjo bolt (22). Install banjo bolt (22) to tube assembly (23).
Position tube assembly (23) onto inlet air control assembly (6). Install install remaining new sealing washer (21) (not shown) to banjo bolt (22). Install banjo bolt (22) finger tight.
Install bolt (17) (not shown) and bolt (24) to clips for tube assembly (23).
Tighten banjo bolt (21) to a torque of 15 N m (133 lb in).
Tighten bolt (17) (not shown) and bolt (24) to a torque of 22 N m (195 lb in).
Install hose assembly onto turbocharger wastegate actuator and slide clip (19) along hose assembly. Note: Ensure that clip for hose assembly is correctly positioned onto the hose assembly.
Position a new hose clamp (18) and a new hose clamp (20) onto hose assembly (26) and hose assembly (27).
Install hose assembly (26) and hose assembly (27) to the connections on the inlet air control assembly (6).
Tighten hose clamp (18) and hose clamp (20) securely.
Illustration 7 g02169793
Illustration 8 g02518536
Hose clamp Type (A)
Hose clamp Type (B)
Loosely install hose clamps (12) for the hose assembly that connects inlet air control assembly (6) to inlet elbow (13). Note: Ensure that the hose clamps are correctly positioned on to hose assembly.
Tighten hose clamps (12) to the correct torque. Refer to Illustration 8 in order to determine the correct type of hose clamp. Tighten hose clamps Type (A) to a torque of 11 N m (97 lb in).Tighten hose clamps Type (B) to a torque of 7 N m (62 lb in).
Connect hose assembly (7) to inlet connection (9) for inlet air control (6). Tighten hose clamps (8) to a torque of 6 N m (53 lb in).
Slide connection for wiring harness assembly for wastegate solenoid (5) onto bracket (2). Connect the engine wiring harness assembly to wiring harness assembly for wastegate solenoid (5). Slide locking tab in to the locked position.