0301827 JOHNSON WASHER

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.
Note: Plug or cap all open ports with new plugs or caps.
If necessary, remove the diesel particulate mounting bracket. Refer to Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedure.
Illustration 1 g02912798
Illustration 2 g02898616
Illustration 3 g02898617
If necessary, remove bolts (1) and heat shield (2) from exhaust gas recirculation (EGR) valve (4).
Slide the locking tab into the unlocked position and disconnect harness assembly (3) from EGR valve (4).
Loosen clamp (6) and position the clamp away from EGR valve (4).
Disconnect hose assembly (5) from EGR valve (4).
Remove bolt (18) from the bracket for tube assembly (19).
Remove bolt (20) and tube assembly (19) from EGR valve (4).
Remove O-ring seal (21) (not shown).
If necessary, slide hose clamp (17) along hose (16). Disconnect tube (19) from hose (16).
Apply releasing fluid prior to and during the removal of bolts (12) and bolts (14).
Remove bolts (12) and remove bolts (14). Remove flexible tube assembly (13) from the exhaust manifold.
Remove bolts (11) from EGR valve (4). Note: Note the position of different length bolts.
Remove from EGR valve (4) from the induction manifold.
If necessary, remove bolt (9) and remove tube assembly (7) from EGR valve (4). Remove O-ring seal (8) (not shown). 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.
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 g02898617
Illustration 5 g02898616
If necessary, install new O-ring seal (8) (not shown) to EGR valve (4). Install tube assembly (7) to EGR valve (4).
Install new clamp (6) to EGR valve (4).
Position a new clamp (6) onto EGR valve (4).
Install bolts (11) to EGR valve (4) finger tight.
Position clamp (6). Tighten the clamp to a torque of 10 N m (89 lb in).
Tighten bolts (11) to a torque of 25 N m (221 lb in). Note: Ensure that the bolts are installed into the correct position.
If necessary, install tube (19) to hose (16). Slide hose clamp (17) into position and tighten securely.
Install new O-ring seals (21) (not shown) to tube assembly (19).
Install tube assembly (19) to EGR valve (4).
Install bolt (18) and bolt (20) finger tight. Tighten the bolt
Tighten bolt (20) to a torque of 10 N m (89 lb in).
Tighten bolt (18) to a torque of 25 N m (221 lb in).
Position new gasket (15) onto flexible tube assembly (13).
Position flexible tube assembly (13) onto the exhaust manifold. Install bolts (14) finger tight. Note: Ensure that the flexible tube assembly can move freely.
Position gasket (10) (not shown) between flexible tube assembly (13) and EGR valve (4). Install bolts (12) finger tight. Note: Ensure that the flexible tube assembly can move freely and the gasket is correctly positioned.
Tighten bolts (12) to a torque of 25 N m (221 lb in).
Tighten bolts (14) to a torque of 25 N m (221 lb in).
Install hose assembly (5) onto pipe (7). Position hose clamp and ti