5034830 JOHNSON *O RING

Illustration 1 g03340452
Disconnect harness assembly (3) from boost pressure sensor (8).
Remove bolts (7) from bracket (6).
Loosen hose clamp (1) disconnect hose assembly (2) (not shown) from the none return valve.
Remove bracket (6) from the cylinder head. Note bracket (6) has the engine wiring harness assembly attached to the bracket.
Loosen hose clamp (9) (not shown) and hose clamp (13) from hose assembly (12).
Remove hose assembly (12) from the outlet of the turbocharger and the inlet manifold.
Remove nut (5) from clip (4) on the tube assembly.
Remove banjo bolt (11) from tube assembly (4).
Remove sealing washers (10).
Remove clip (4) on the tube assembly from the stud nut.
Illustration 2 g03340453
Loosen hose clamp (19) (not shown for hose assembly (18). Remove the hose assembly from close circuit breather canister (21).
Loosen hose clamp (15) (not shown) and hose clamp (17) (not shown) for hose assembly (16).
Remove bolts (21) from bracket (23) and close circuit breather canister (21).
Remove hose assembly (16) and close circuit breather canister (21) from valve mechanism cover (26).
Remove bolts (20) and stud bolt (14) (not shown) from valve mechanism cover (26).
Remove nuts (24) from valve mechanism cover (26). Note: Loosen the nuts evenly in order to avoid distortion of the valve mechanism cover.
Remove sealing washers (25) (not shown) from the studs.
Remove valve mechanism cover (26) from valve mechanism base (27).
Remove gasket (28) (not shown) from valve mechanism cover (26).
Illustration 3 g03340745
If necessary, follow Step 22.a through Step 22.c in order to remove inlet elbow (30) from valve mechanism cover (26).
Remove bolts (31) from inlet elbow (30).
Remove inlet elbow (30) from valve mechanism cover (26).
Remove gasket (32) (not shown).
If necessary, remove crankcase breather (33) from valve mechanism cover (26). Refer to Disassembly and Assembly, "Crankcase Breather - Remove and Install" for the correct procedure.
If necessary, remove boost pressure sensor (8) from inlet elbow (30). Refer to Disassembly and Assembly, "Boost Pressure Sensor - Remove and Install" for the correct procedure. Installation Procedure
Illustration 4 g03340745
If necessary, follow Step 1.a through Step 1.e in order to install inlet elbow (30) to valve mechanism cover (26).
Ensure that inlet elbow (30) is clean and free from damage. Clean the gasket surfaces of inlet elbow (30).
Position a new gasket (32) (not shown) onto inlet elbow (30).
Position inlet elbow (30) onto valve mechanism cover (26). Ensure that the inlet elbow is correctly orientated.
Install bolts (31) to inlet elbow (30) hand tight.
Tighten bolts (31) to a torque of 10 N m (89 lb in).
If necessary, install crankcase breather (33) to valve mechanism cover (26). Refer to Disassembly and Assembly, "Crankcase Breather - Remove and Install" for the correct procedure.
If necessary, install boost pressure sensor (8) to inlet elbow (30). Refer to Disassembly and Assembly, "Boost Pressure Sensor - Remove and Install" for the correct procedure.
Illustration 5 g03340453
Ensure that valve mechanism cover (26) is clean and free from damage. Clean the gasket surface of valve mechanism base (27).
Install a new gasket (28) (not shown) to valve mechanism cover (26). Ensure that the gasket is correctly seated into the recess of the valve mechanism cover.
Position valve mechanism cover (26) onto base (27).
Install bolts (20) and stud bolt (14) (not shown) to valve mechanism cover (26) finger tight.
Install new sealing washers (25) (not shown) onto the studs.
Install nuts (24) finger tight.
Tighten bolts (20) and stud bolt (14) (not shown) to a torque of 10 N m (89 lb in).
For C1.5 engines, tighten evenly nuts (24) to a torque of 14 N m (124 lb in). Note: Tighten the nuts evenly in order to avoid distortion of the valve mechanism cover.
Repeat Step 10 through Step 11 in order to ensure the bolts (20), stud bolt (14), and nuts (24) achieve the correct torque values.
Install hose assembly (16) and close circuit breather canister (21) to valve mechanism cover (26). Ensure that the hose clamps a correctly orientated.
Install bolts (21) to bracket (23) and close circuit breather canister (21).
Tighten bolts (21) to a torque of 10 N m (89 lb in).
Tighten hose clamp (15) (not shown) and hose clamp (17) (not shown) for hose assembly (16) securely.
Install hose assembly (18) to close circuit breather canister (21). Tighten hose clamp (19) (not shown) securely.
Illustration 6 g03340452
Connect harness assembly (3) to boost pressure sensor (8).
Position a new sealing washer (10) onto banjo bolt (11).
Install banjo bolt (11) to tube assembly (4). Install the remaining new sealing washer (10) between the tube assembly and the turbocharger.
Install clip (4) on the tube assembly to the stud nut. Install nut (5) to clip (4) on the tube assembly.
Tighten nut (5) to a torque of 10 N m (89 lb in).
Tighten banjo bolt (11) to a torque of 20 N m (177 lb in).
Position bracket (6) onto the cylinder head and connect hose assembly (2) (not shown) to the none return valve. Note bracket (6) has the engine wiring harness assembly attached to the bracket.
Install bolts (7) to the bracket.
Tighten bolts (7) to a torque of 10 N m (89 lb in).
Tighten hose clamp (1) securely.
Install hose assembly (12) to the outlet of the turbocharger and the inlet manifold.
Tighten hose clamp (9) (not shown) and hose clamp (13) securely.
If necessary, install the bracket for the Clean Emission Module (CEM). Refer to Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedure.
If necessary, install the air cleaner bracket. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install" for the correct procedure.