0211106 JOHNSON OWNERS MANUAL, 90/110

Table 1
Required Tools
Tool Part Number Part Description Qty
A 438-6765 Cap 2
B - Capping Kit 1 Start By:
Remove the flexible exhaust pipe. Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Turn the battery disconnect switch to the OFF position.
Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure.
Remove the Original Equipment Manufacturers (OEM) exhaust system from the Clean Emissions Module (CEM). Refer to the OEM for the correct procedure.
Illustration 1 g03388280
Typical example
Make temporary marks on harness assemblies (1). Disconnect the harness assemblies from the soot antenna. Refer to Disassembly and Assembly, "Soot Antenna - Remove and Install" for the correct procedure.
Remove bolts (5) and place the harness assemblies away from the CEM.
Remove nitrogen oxide sensor (2). Refer to Disassembly and Assembly, "Nitrogen Oxide Sensor - Remove and Install" for the correct procedure.
Remove Diesel Emission Fluid (DEF) (4) from the DEF injector. Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure.
Disconnect harness assembly (3) from the Diesel Emission Fluid (DEF) injector. Use Tooling (A) to caps the harness connection and the DEF injector.
Make temporary marks on hose assembly (7) and hose assembly (8). Disconnect the hose assemblies from the DEF injector. Use Tooling (B) to plugs the hose assemblies. Use Tooling (B) to caps the DEF injector.
Remove bolts (6) from the clips for hose assembly (7) and hose assembly (8). Position the hose assemblies away from the CEM.
Illustration 2 g03388284
Typical example
Disconnect harness assemblies from the connection (5) and connection (6) on the CEM.
Attach a suitable lifting device to the CEM. The weight of CEM is approximately 129 kg (284 lb).
Illustration 3 g03388329
Typical example
Remove bolts (12).
Remove washers (13) and upper vibration mounts (14) from bracket (16).
Use the suitable lifting device to remove assembly CEM (11) from the mounting brackets.
Remove lower vibration mounts (17) and spacer (15).
Illustration 4 g03388381
Typical example
Place CEM (11) on a suitable support.
If necessary, remove bolts (18) from bracket (16).
Use the suitable lifting device to remove assembly CEM (11) from brackets (16).Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
C - Guide Studs
M16 by 110 mm 4
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Illustration 5 g03388381
Typical example
Attach a suitable lifting device to CEM (11). The weight of clean emissions module is approximately 129 kg (284 lb).
Use the suitable lifting device to position assembly CEM (11) onto brackets (16).
Install bolts (18) to bracket (16) and CEM (11).Tighten the bolts to a torque of 190 N m (140 lb ft).
Illustration 6 g03388329
Typical example
Install Tooling (C) to the front bracket and the rear bracket.
Position lower vibration mounts (17) and spacers (15) onto the front bracket and the rear bracket. Ensure that the lower vibration mounts are correctly orientated.
Use the suitable lifting device to install the assembly CEM (11) onto lower vibration mounts (17) and the