0281780 JOHNSON MOTOR COVER ASSEMBLY

Assembly Procedure (Horizontally Mounted Particulate Filter)
Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     5P-3931     Anti-Seize Compound     -    
B     1S-0258     Plastic Hammer As     1    Note: When the sections are installed, maintain the original direction of the flow of exhaust. The sections must maintain the original direction of the flow of exhaust in order to comply with emissions standards.
Illustration 1 g01458222
Note: Install new gasket. Refer to Special Instructions, "Procedure for cleaning ash from the Diesel Particulate Filter (DPF)".
Position the new gasket (not shown) and connect inlet section (9) onto filter section (7) .
Position the new gasket (not shown) and connect outlet section (6) onto filter section (7) .
Install band clamps (8) and hand tighten the band clamps.
Align the marks at Point (E) on the filter section and the exterior of the inlet and outlet sections.
Use Tooling (B) in order to tap gently band clamps (8) around the diesel particulate filter in one full rotation. This process is used to seat the band clamps.Note: Verify that sections (6) , (7) , and (9) remain in original positions.
Position band clamps (8) into original positions. Tighten band clamps (8) to a torque of 11 1 N m (100 10 lb in).
Illustration 2 g01454590
Apply Tooling (A) to the threads on fittings (3) , (4) , and (5) .
Install fittings (5) and tighten the fittings to a torque of 24 4 N m (208 35 lb in).
Position temperature sensor (2) into the original position.
Tighten fitting (3) to a torque of 45 5 N m (33 4 lb ft). Repeat this step for the opposite side.
Tighten fitting (4) to a torque of 8 2 N m (71 18 lb in). Repeat this step for the opposite side.
Illustration 3 g01458162
Position clamps (1) , as shown. Tighten clamps (1) to a torque of 8.5 1 N m (75 10 lb in).
Reset the engine ash model. Refer to the section "Ash Service Reset".Assembly Procedure (Vertically Mounted Particulate Filter)
Table 2
Required Tools    
Tool     Part Number     Part Description     Qty    
A     5P-3931     Anti-Seize Compound     -    
B     1S-0258     Plastic Hammer As     1    Note: When the sections are installed, maintain the original direction of the flow of exhaust. The sections must maintain the original direction of the flow of exhaust in order to comply with the emissions standards.
Illustration 4 g01460747
Note: Install new gasket. Refer to Special Instructions, "Procedure for cleaning ash from the Diesel Particulate Filter (DPF)".
Position the new gasket (not shown) and connect inlet section (18) onto filter section (11) .
Install band clamp (19) and hand tighten the band clamp.
Position mounting assemblies (16) and clamp assemblies (17) at Point (H) .
Tighten clamp assemblies (17) to a torque of 11 1 N m (100 10 lb in).
Illustration 5 g01459892
Note: Install new gasket. Refer to Special Instructions, "Procedure for cleaning ash from the Diesel Particulate Filter (DPF)".
Position the new gasket (not shown) and connect outlet section (15) onto filter section (11) .
Install band clamp (12) and hand tighten the band clamp.
Position mounting assembly (14) and clamp assembly (13) at Point (G) .
Tighten clamp assembly (13) to a torque of 11 1 N m (100 10 lb in).
Illustration 6 g01460767
Align the marks at Point (F) on filter section (11) , inlet section (18) , and outlet section (15) .
Use Tooling (B) in order to tap gently band clamps (19) and (12) around the diesel particulate filter in one full rotation. This process is used to seat the band clamps.Note: Verify that sections (18) , (11) , and (15) remain in original positions.
Position band clamps (19) and (12) into original positions. Tighten the band clamps to a torque of 11 1 N m (100 10 lb in).