0398843 JOHNSON ENGINE COVER ASSY.

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.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g06146962
Remove bolts (4) and remove cooler (3) from exhaust gas recirculation valve assembly (1). Ensure that the tube assemblies on the cooler are not strained as the exhaust gas recirculation valve assembly is removed.
Remove gasket (5).
Remove O-ring seal (6) (not shown) from exhaust gas recirculation valve assembly (1).
Remove differential pressure and absolute pressure sensor (2) from exhaust gas recirculation valve assembly (1). Refer to Disassembly and Assembly, Pressure Sensor (Cooled Exhaust Gas) - Remove and Install for the correct procedure.Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - International Products P-80 Emulsion Rubber Assembly Lubricant 1
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.
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 2 g06146962
Ensure that the gasket surfaces of exhaust gas recirculation valve assembly (1) and cooler (3) are clean and free from damage.
Install differential pressure and absolute pressure sensor (2) to exhaust gas recirculation valve assembly (1). Refer to Disassembly and Assembly, Pressure Sensor (Cooled Exhaust Gas) - Remove and Install for the correct procedure.
Install a new gasket (5) to cooler (3).
Use Tooling (A) to lubricate a new O-ring seal (6) (not shown). Install the O-ring seal to exhaust gas recirculation valve assembly (1).
Install cooler (3) to exhaust gas recirculation valve assembly (1). Ensure that the tube assemblies on the cooler are not strained as the exhaust gas recirculation valve assembly is installed.
Install bolts (4) to exhaust gas recirculation valve assembly (1). Hand tighten the bolts.
Install the exhaust cooler for the NOx Reduction System (NRS) Disassembly and Assembly, Exhaust Cooler (NRS) - Remove and Install for the correct procedure.
After the installations of the exhaust cooler assembly, tighten bolts (4) to a torque of 22 N m (195 lb in). Ensure that the tube assemblies of the exhaust cooler are not strained as the bolts are tightened.
If a new EGR valve is install, use the electronic service tool to perform the "EGR Valve Replacement Reset". Refer to Troubleshooting, "Service Tool Features" for more information.
Use the electronic service tool to perform the "Air Systems Motor Valve Verification Test". Refer to Troubleshooting, "Service Tool Features" for more information.