5036322 JOHNSON PINION

At temperatures lower than −15° C (5° F), care should be taken when removing the Diesel Exhaust Fluid (DEF) line connectors that are attached to the tank, pump, and injector. To limit possible damage to the DEF line connectors, carefully apply heat to the area of the DEF line connectors.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
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 disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.
Illustration 1 g03417800
Typical example
Make temporary mark on harness assembly (3) to show routing of the harness assembly for installation purposes.
Cut cable straps (4) from harness assembly (3).Note: Note position of all cable straps that retain the harness assembly in position.
Cut cable strap (2).
Disconnect harness assembly (3) from harness assembly (1).
Illustration 2 g03407564
Typical example
Loosen hose clamp (6) on hose assembly (5).
Disconnect hose assembly (5) from manifold Diesel Emission Fluid (DEF) heater (8). Position the hose assembly away from the manifold DEF heater.
Loosen hose clamp (12) on hose assembly (11).
Disconnect hose assembly (11) from manifold DEF heater (8). Position the hose assembly away from the manifold DEF heater.
Disconnect diesel exhaust fluid line (7) from manifold DEF heater (8). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure. Position the diesel exhaust fluid line away from the manifold DEF heater.
Disconnect diesel exhaust fluid line (13) from manifold DEF heater (8). Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Lines - Remove and Install" for the correct procedure. Position the diesel exhaust fluid line away from the manifold DEF heater.
Remove screws (10) from manifold DEF heater (8).
Remove plate (9) from manifold DEF heater (8).
Remove manifold DEF heater (8) from DEF tank (14).
Remove gasket (15) (not shown).
Illustration 3 g03417821
If necessary, follow Step 17.a through Step 17.c to remove filter (16) from manifold DEF heater (8).
Pull locking Tabs (A) outward.
Remove filter (16) the pickup pipe on manifold DEF heater (8).
Remove O-ring seal (17) from filter (16).Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Distilled Water -
De-ionized Water
Diesel Exhaust Fluid (DEF)
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Illustration 4 g03417821
Typical example
If necessary, follow Step 2.a through Step 2.e to remove filter (16) from manifold DEF heater (8).
Ensure that filter (16) is free from restriction and free damage.
If necessary, install a new O-ring seal (17) to filter (16). Ensure that the new O-ring seal is correctly is located against the internal shoulder.
Use Tooling (A) to lubricate O-ring seal (17).
Install filter (16) to the pickup pipe on manifold DEF heater (8).
Ensure that filter (16) is securely located into the locking Tabs (A).
Illustration 5 g03407564
Typical example
Clean gasket surfaces of DEF tan