0391519 JOHNSON MOTOR COVER,Lower

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 g03456496
Loosen the hose clamps and disconnect the hose assembly from connection (9) for inlet air control (8).
Disconnect engine wiring harness assembly (1) from wiring harness assembly (5) for NRS valve (7). Slide the connection for wiring harness assembly (5) from bracket (3).
Disconnect engine wiring harness assembly (2) from wiring harness assembly (4) for wastegate solenoid (6). Slide connection for wiring harness assembly (4) from bracket (3).
Loosen hose clamps (10) on the hose assembly that connects inlet air control assembly (8) to inlet elbow (11).
Illustration 2 g03456497
Remove temperature sensor (16) from inlet air control assembly (8). Refer to Disassembly and Assembly, "Temperature Sensor (Cooled Exhaust Gas) - Remove and Install" for the correct procedure.
Slide clip (12) along hose assembly (13). Disconnect the hose assembly from the wastegate actuator.
Remove bolt (15) for the tube assembly for the wastegate actuator.
Remove bolts (14).
Illustration 3 g03456498
Release hose clamp (18) for hose assembly (19). Remove the hose assembly from inlet air control assembly (8).
Release hose clamp (20) for hose assembly (21). Remove the hose assembly from inlet air control assembly (8).
Remove banjo bolt (23) and remove sealing washers (22) (not shown).
Remove bolt (24) from tube assembly (25). Remove the tube assembly from inlet air control assembly (8).
Remove bolts (26) inlet air control assembly (8).
Remove inlet air control assembly (8).
Remove gasket (17) (not shown).
Illustration 4 g03456499
Cut cable straps (30).Remove bolts (27).Remove bracket (28) from cylinder head (29).Installation Procedure
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.
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Illustration 5 g03458958
If necessary, follow Step 1 through Step4 to install bracket (28).
Position bracket (28) onto cylinder head (29).
Install bolts (27) hand tight. Ensure that rubber sleeve (31) is correctly positioned into recess of bracket (28).
Tighten bolts (27) to a torque of 22 N m (195 lb in).
Install new cable straps (30).Note: Ensure that the cable straps meet the Original Equipment Manufacturer (OEM) specification.
Illustration 6 g03458960
Illustration 7 g03458961
Position a new gasket (17) onto inlet air control assembly (8). Ensure gasket (17) is correctly installed into locating Pins (X).
Loosen bolts (33) for bracket (32).