0396726 JOHNSON WATER PUMP REPAIR KIT

Introduction
Note: The information that is contained in this Special Instruction applies to the C3.4B engine with the through flow Diesel Particulate Filter (DPF) installed.The correct installation of emissions critical components is vital to comply with the relevant emissions legislation. In addition, the document highlights the key assembly characteristics of other components that are transported loose. The assembly of the loose components is carried out by a representative of the customer.This Special Instruction is to be used in addition to the Service Manual. This document should be used as an assembly guide or a reference document when developing processes for production assembly facilities. Critical assembly characteristics such as tightening torques, component orientation, and assembly sequences must be followed to achieve the required product quality and emissions regulations.The Service Manual consists of the following manuals.
Operation and Maintenance Manual
Disassembly and Assembly
Troubleshooting
Systems Operation Testing and Adjusting
SpecificationsCustomers are permitted to paint the engine as received or as part of a power train sub assembly. These engines are supplied in gray primer.The customer must not paint the aftertreatment or exhaust systems, Electronic Control Module (ECM), starting motor, alternator, belts, or the glow plug control unit. The customer is also not permitted to paint any filters and filter canisters. The canisters include fuel, air, oil, crankcase breather, or DEF.The customer is required to use suitable plugs and masks to the equivalent standard used in the engine assembly plant.The customer must prevent water ingress into the engine by maintaining an equivalent to the standard used in the engine assembly plant.Engine Air Cleaner for C7.1 and C4.4 Engines
Illustration 1 g03179402
Typical example
The engine air cleaner (1) can be supplied as a loose assembly. The engine air cleaner should be mounted horizontally. The dust exhaust port should be at the lowest point and positioned in a direction that is down.Note: Do not paint the dust exhaust port. Solvents and chemicals will shorten the usable life of the exhaust port.Note: There are several variations of engine air cleaner.Select the appropriate sized fasteners for the relevant air cleaner. Bolts should have a flanged head or be installed with a washer under the bolt head.Standard duty air cleanerTighten the M10 bolts to the following torque. ... 38.5 5.5 N m (28.4 4.1 lb ft)Heavy-duty air cleanerTighten the M8 bolts to the following torque. ... 15 3 N m (133 27 lb in)
Illustration 2 g03415816
Typical example
The position of the clamp (2) in relation to pipe or component bead (3) is crucial. Ensure that clamp (2) is installed on the correct side of the pipe or component bead (3).Air Temperature Sensor for C7.1 and C4.4 Engines
The air temperature sensor can be supplied loose.
Illustration 3 g03178776
Typical example
Install the sensor (1). Tighten the sensor to a torque of 20 3 N m (177 27 lb in).Note: Ensure that the O-ring is correctly installed to the sensor. Do not lubricate the O-ring seal.Fan for C7.1 and C4.4 Engines
The fan can be supplied loose.
Illustration 4 g03178780
Typical example
Remove locking nuts (1) from studs (3).
If studs (3) have not been previously removed from fan drive, check for the correct installation of the studs to the fan drive. Tighten studs (3) to a torque of 11 3 N m (97 27 lb in).
Install fan (2) to studs (3).Note: Ensure that the label "Radiator Side" is visible once the fan is installed from the front of the engine.
Inspect the condition of locking nuts (1). If necessary, replace the locking nuts. Install locking nuts (1). Tighten locking nuts to a torque of 22 5.5 N m (195 49 lb in).Flexible Exhaust Pipe for C7.1 Engines