0434004 EVINRUDE OWNERS MANUAL, Jo.

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.
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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.
Turn the battery disconnect switch to the OFF position.
Remove the tube assembly (not shown) from connection (12).
Disconnect harness assembly (8) from connection (9), Pressure sensor (10), and NOx Reduction System (NRS) valve (11).
Disconnect harness assembly (8) from wastegate solenoid (13) and cooled exhaust gas temperature sensor (14).
Cut cable straps (4) and position harness assembly (8) away from bracket (3).
Remove bolts (2) and bracket (3) from the inlet manifold.
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If necessary, remove cooled exhaust gas temperature sensor (14). Refer to Disassembly and Assembly, "Temperature Sensor (Cooled Exhaust Gas) - Remove and Install" for the correct procedure.
Disconnect tube assembly (15) from exhaust gas cooler (1).
Remove bolts (16) and bolts (20) from exhaust gas cooler (1). Remove the exhaust gas cooler (1) from NRS valve assembly (11) and inlet manifold (19).Note: The exhaust cooler should be supported as the bolts are removed.
Remove gasket (18) (not shown) and gasket (21) (not shown). Note the orientation of the gaskets for installation purposes.
Remove O-ring seal (17) (not shown).Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - P-80 Emulsion Rubber Assembly Lubricant 1
Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness and the convoluting.
Ensure that the exhaust gas cooler is clean and free from restriction. Ensure that the exhaust cooler is free from wear and damage. If necessary, replace any components that are worn or damaged.Note: The NRS exhaust gas cooler should not be cleaned.
Ensure that all tube assemblies are free from restriction and damage.
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Apply Tooling (A) to new O-ring seal (17). Install new O-ring seal (17) to NOx Reduction System (NRS) assembly (11).
Install bolts (16) and gasket (18) to NRS assembly (11).
Install bolts (20) and gasket (21) (not shown) to NRS assembly (11).Note: The gasket should be fitted so the side tab is on the left-hand side with part number facing inwards.
Position exhaust gas cooler (1) onto inlet manifold and NRS assembly (11). Tighten bolts (16) and bolts (20) hand tight.Note: The exhaust gas cooler should be supported as the bolts are installed.
Tighten bolts (16) and bolts (20) to a torque of 22 N m (195 lb in).
Install hose assembly (15) to exhaust gas cooler (1) and tighten the hose clamp securely.
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Position bracket (3) onto the exhaust gas cooler. Install bolts (2) and tighten the bolts to a torque of 22 N m (195 lb in).
If necessary, install cooled exhaust gas temperature sensor (14). Refer to Disassembly and Assembly, "Temperature Sensor (Cooled Exhaust Gas) - Remove and Install" for the correct procedure.
Reposition harness assembly (4). Connect harness assembly (8) to connection (9), pressure sensor (10), and NOx Reduction System (NRS) valve (11).
Reinstall the tube assembly (not shown) to connection (12) and tighten securely.
Connect harness assembly (8) to wastegate solenoid (13) and cooled exhaust gas temperature sensor (14).
Install new cable straps (4) to wiring harness assembly (8).Note: Ensure that the cable straps meet the Original Equipment Manufactures (OEM) specification.
Turn the battery disconnect switch to the ON position.
Fill the cooling system wi