0397128 EVINRUDE PINION ASSY.

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.
Illustration 1 g03329695
Loosen hose clamp (11) on hose assembly (10). Disconnect hose assembly (10) from exhaust cooler (NRS) (7).
Loosen hose clamp (9) on hose assembly (8). Disconnect hose assembly (8) from exhaust cooler NRS) (7).
Remove bolts (2) and bolts (6) from tube assembly (1).
Remove tube assembly (1) from exhaust cooler (NRS) (7) and exhaust gas recirculation (EGR) valve assembly (4).
Remove gasket (3) (not shown) and gasket (5) (not shown).
Illustration 2 g03329706
Remove bolts (12) from exhaust cooler (NRS) assembly (7).
Remove gasket (14) (not shown) from between exhaust manifold (13) and exhaust cooler (NRS) assembly (7).
Remove bolt (17) from bracket (16). Support exhaust cooler (NRS) assembly (7) as the bolt (17) is removed.
Remove exhaust cooler (NRS) assembly (7).
Plug and cap all open ports on exhaust cooler (NRS) assembly (7).
If necessary, remove nut (15) and remove bracket (16). Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Anti-Seize Compound 1
Check all components for wear and damage. If necessary, replace any components that are worn or damaged.
Illustration 3 g03329706
Ensure that the exhaust cooler (NRS) assembly is free from restriction and external damage. Ensure that the exhaust cooler (NRS) assembly and tube assemblies are free from wear and damage. Refer to Systems Operation Testing and Adjusting, "Exhaust Cooler (NRS) - Test" for the correct inspection procedure. Note: Cleaning of the internal core of the exhaust cooler (NRS) should not be carried out.
Clean the gasket surfaces of exhaust cooler (NRS) assembly (7) and exhaust manifold (13).
If necessary, position bracket (16) onto exhaust cooler (NRS) assembly (7). Ensure that the bracket is correctly orientated.
Loosely install nut (15).
Remove plug and cap from all open ports of exhaust cooler (NRS) assembly (7)
Position exhaust cooler (NRS) assembly (7) onto the cylinder block.
Install bolt (17) to bracket (16). Support exhaust cooler (NRS) assembly (7) as bolt (17) is installed.
Position a new gasket (14) (not shown) between exhaust manifold (13) and exhaust cooler (NRS) assembly (7).
Apply Tooling (A) to the threads of bolts (12). Install bolts (12) to exhaust cooler (NRS) assembly (7) hand tight.
Tighten bolts (12) to a torque of 25 N m (221 lb in).
Tighten bolt (17) to a torque of 25 N m (221 lb in).
Tighten locking nut (15) to a torque of 25 N m (221 lb in). Ensure that bracket (16) is not stranded as the nut is tightened.
Illustration 4 g03329695
Connect hose assembly (10) to exhaust cooler (NRS) (7). Tighten hose clamp (11) securely.
Connect hose assembly (8) to exhaust cooler (NRS) (7). Tighten hose clamp (9) securely.
Clean the gasket surfaces of tube assembly (1) and exhaust gas recirculation (EGR) valve assembly (4).
Apply Tooling (A) to the threads of bolts (2) and bolts (6).
Position a new gasket (3) (not shown) and a new gasket (5) (not shown) onto tube assembly (1).
Position tube assembly (1) onto exhaust cooler (NRS) (7) and exhaust gas recirculation (EGR) valve assembly (4).
Install bolts (2) and bolts (6) to tube assembly (1). Hand tighten the bolts.
Tighten bolts (2) and bolts (6) to a torque of 25 N m (221 lb in). Ensure that tube assembly (1) is not stranded as the bolts are tightened. End By:
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.