5034827 JOHNSON *O RING

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g03346731
Remove bolt (4) (not shown) and bolt (10). Position bracket (5) away from the Inlet manifold.
Disconnect harness assembly (3).
Remove bolts (1) from bracket (2). Position the bracket away from the inlet manifold.
Loosen hose clamp (11) (not shown) and hose clamp (14).
Remove hose assembly (13) from turbocharger (12) and the inlet manifold.
Remove tube assembly (8) from Exhaust Gas Recirculation (EGR) valve (9) and the EGR cooler. Refer to Disassembly and Assembly, "Exhaust Cooler (NRS) - Remove and Install" for the correct procedure.
Disconnect harness assembly (6) from boost pressure sensor (7).
Illustration 2 g03346746
Remove bolts (14) from the assembly of inlet manifold (15).
Remove inlet manifold (15) and adaptor (16) from the cylinder head.
Remove gasket (18) (not shown) and gasket (17) (not shown).
If necessary, remove boost pressure sensor (6) from inlet manifold (15). Refer to Disassembly and Assembly, "Boost Pressure Sensor - Remove and Install" for the correct procedure.
If necessary, remove EGR valve (8) from inlet manifold (15). Refer to Disassembly and Assembly, "Exhaust Gas Recirculation Valve - Remove and Install" for the correct procedure. Installation procedure
Table 1
Required Tools
Tool Part Number Description Qty
A - Guide Stud
(M6 x 1.00 by 100 mm) 2
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Inspect all components for wear and damage. If necessary, replace any components that are worn or damaged.
Clean the gasket surfaces of the inlet manifold, adaptor, and the cylinder head.
Illustration 3 g03349412
If necessary, install boost pressure sensor (6) to inlet manifold (15). Refer to Disassembly and Assembly, "Boost Pressure Sensor - Remove and Install" for the correct procedure.
If necessary, install EGR valve (8) to inlet manifold (15). Refer to Disassembly and Assembly, "Exhaust Gas Recirculation Valve - Remove and Install" for the correct procedure.
Install Tooling (A) in Positions (X).
Position a new gasket (17) (not shown) onto the cylinder head. Ensure that the gasket is correctly orientated. Position adaptor (16) onto the cylinder head.
Position gasket (18) (not shown) onto adaptor (16). Ensure that the gasket is correctly orientated. Position inlet manifold (15) onto adaptor (16).
Install bolts (14) to the assembly of inlet manifold (15).
Remove Tooling (A) and install remaining bolts (14).
Tighten bolts (14) to a torque of 10 N m (89 lb in).
Illustration 4 g03346731
Install tube assembly (8) to Exhaust Gas Recirculation (EGR) valve (9) and the EGR cooler. Refer to Disassembly and Assembly, "Exhaust Cooler (NRS) - Remove and Install" for the correct procedure.
Install hose assembly (13) to turbocharger (12) and the inlet manifold.
Securely tighten hose clamp (11) (not shown) and hose clamp (14).
Position bracket (5) onto from the Inlet manifold. Install bolt (4) (not shown) and bolt (10).
Tighten (10) (not shown) to a torque of 25 N m (221 lb in). Tighten (4) (not shown) to a torque of 10 N m (89 lb in).
Position bracket (2) onto the inlet manifold.
Install bolts (1) to bracket (2). Tighten the bolts to a torque of 10 N m (89 lb in).
Connect harness assembly (3).
Connect harness assembly (6) to boost pressure sensor (7).