0383757 JOHNSON GEARCASE HEAD 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.
Illustration 1 g02619678
Remove clip (7) and clip (12) from tube assembly (3) and tube assembly (6).
Remove banjo bolt (2) from tube assembly (3). Remove sealing washers (1) (not shown).
Remove banjo bolt (9) from tube assembly (6). Remove sealing washers (13) (not shown).
Remove tube assembly (6).
remove bolt (8) from clip for tube assembly (6).
Remove bolts (5) and bolts (11) from tube assembly (6).
Remove tube assembly (6) from the turbo charger and the cylinder block.
Illustration 2 g02619657
Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.
Remove bolts (14) and bolts (23) from tube assembly (15).
Remove tube assembly (15) from exhaust cooler (25) and the cylinder head.
Remove gaskets (16) (not shown) and gasket (24) (not shown) from tube assembly (15).
Prior to and during removal of bolts (17) and bolts (29) apply releasing fluid to the bolts. Remove bolts (17) and bolts (29) from tube assembly (19).
Remove tube assembly (19) from exhaust cooler (25) and the exhaust manifold.
Remove gaskets (18) (not shown) and gasket (28) (not shown) from tube assembly (19).
Remove bolts (21) and bolts (27) from tube assembly (20).
Remove tube assembly (20) from exhaust cooler (25) and the cylinder head.
Remove gasket (22) (not shown) and gasket (26) (not shown) from tube assembly (20).
Illustration 3 g02619659
Cut cable straps (34) for wiring harness assembly (30). Ensure that all the cable straps are removed from all harness assemblies.
Slide locking tab (31) into the unlocked position. Disconnect wiring harness assembly (30) from engine wiring harness assembly (32).
Remove bolts (33) from tube assembly (36).
Remove bolt (37) from clamp on tube assembly (36).
Remove bolts (38) from tube assembly (36).
Remove tube assembly (36). Remove gasket (35) (not shown) and gasket (39) (not shown) from tube assembly (36).
Illustration 4 g02619660
Remove bolt (40) and bolts (41) from exhaust cooler (25). Note: The exhaust cooler should be supported as the bolts are removed.
Remove exhaust cooler (25) from the cylinder block. Installation Procedure
Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness and the convoluting.
Ensure that the exhaust cooler is clean and free from restriction. Ensure that the exhaust cooler is free from wear and damage. If necessary, replace any components that are worn or damaged. Note: The NRS exhaust cooler should not be disassembled or cleaned.
Ensure that all tube assemblies are free from restriction and damage.
Illustration 5 g02619660
Position exhaust cooler (25) onto the cylinder block. Install bolt (40) and bolts (41) to exhaust cooler (25). Hand tighten bolt (40) and bolts (41). Note: The exhaust cooler should be supported as the bolts are installed.
Tighten bolt (40) and bolts (41) to a torque of 22 N m (195 lb in).
Illustration 6 g02619659
Position a new gasket (35) (not shown) and a new gasket (39) (not shown) onto tube assembly (36).
Position tube assembly (36) onto the exhaust cooler and the inlet air control. Install bolts (33) and bolts (38) to tube assembly (36).
Install bolt (37) to clamp on tube assembly (36).
Tighten bolts (33) to a torque of 9 N m (80 lb in). Tighten bolts (38) to a torque of 18 N m (159 lb in).Tighten bolt (37) to a torque of 22 N m (195 lb in).
Connect wiring harness assembly (30) to engine wiring harness assembly (32). Slide locking tab (31) into the locked position.
Install new cable straps (34) to wiring harness assembly (30). Note: Ensure that the cable straps meet the Original Equipment Manufactures (OEM) specification.
Illustration 7 g02619657
Position a new gasket (16) (not shown) and a new gasket (24) (not shown) onto tube assembly (15).
Install tube assembly (15) to exhaust cooler (25) and the cylinder head.
Install bolts (14) and bolts (23) to tube assembly (15).
Tighten bolts (23) to a torque of 18 N m (159 lb in). Tighten bolt (14) to a torque of 22 N m (195 lb in).
Position a new gasket (22) (not shown) and install a new gasket (26) (not shown) onto tube assembly (20).
Position tube assembly (20) onto exhaust cooler (25) and the cylinder head. Install bolts (21) and bolts (27) to tube assembly (20). Ensure that the tube assembly is correctly positioned into the exhaust cooler.
Tighten bolt (21) and bolts (27) to