821759A 2 Mercruiser CARRIER ASSEMBLY

Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.
The muffler, catalytic converter/muffler, and diesel particulate filter will become extremely hot during engine operation. A hot muffler, catalytic converter/muffler and diesel particulate filter can cause serious burns. Allow adequate cooling time before working on or near the muffler, catalytic converter/muffler and diesel particulate filter.
Do not strike any part of the assembly of the Diesel Particulate Filter (DPF). Do not allow any object to contact the internal element of the DPF. If the internal element of the DPF becomes damaged, the assembly must be replaced.Do not use power tools in order to disassemble or assemble any part of the Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), or the outlet section.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that all the components of the diesel particulate filter, the canister, and the end cap are free from wear or damage. If necessary, replace any component that is worn or damaged.
Illustration 1 g03344438
If necessary, follow Step 2.a through Step 2.f in order to assemble the assembly of diesel particulate filter canister (1).
Clean the gasket surfaces of end cap (20), diesel particulate filter (23), and diesel particulate filter canister (1).
Position a new gasket (24) onto canister (27). Ensure that the holes in the gasket are correctly aligned with the canister.
Install diesel particulate filter (22) to canister (27). Ensure that the temporary marks are aligned.
Position a new gasket (22) onto diesel particulate filter (23). Ensure that the holes in the gasket are correctly aligned with the diesel particulate filter.
Install end cap (20) to diesel particulate filter (22). Ensure that the temporary marks are aligned and that the holes in the gasket are correctly aligned with the end cap.
Install bolts (21) and nuts (26) hand tight. Tighten the nuts and bolts to a torque of 15 N m (133 lb in).
Illustration 2 g03344807
Position a new gasket (13) (not shown) onto exhaust elbow (14).
Position diesel particulate filter canister (1) onto mounting bracket (19). Ensure that the diesel particulate filter canister is correctly positioned onto the studs in the exhaust elbow.
Install the nuts and bolts (15) and nuts (12) to exhaust elbow (14) hand tight.
Position bracket (9) onto the diesel particulate filter canister (1). Install the nuts and bolt (10) and nuts and bolt (16) to the bracket. Hand tighten the nuts and bolts. Ensure that when the nuts and bolts are tightened that there is equal cap in Position (X) between both brackets.
Position bracket (17) onto the diesel particulate filter canister (1). Install the nuts and bolt (11) and nuts and bolt (18) to the bracket. Hand tighten the nuts and bolts. Ensure that when the nuts and bolts are tightened that there is equal cap in Position (X) between both brackets.
Tighten the nuts and bolts (15) and nuts (12) to a torque of 25 N m (221 lb in).
Tighten the nuts and bolt (10), nuts and bolt (16), nuts and bolt (11), and nuts and bolt (18) to a torque of 15 N m (133 lb in). Ensure that when the nuts and bolts are tightened that there is equal cap in Position (X) between both brackets.
Illustration 3 g03344436
Install outlet temperature sensor (8) to diesel particulate filter canister (1). Refer to Disassembly and Assembly, "Temperature Sensor (DPF) - Remove and Install" for the correct procedure.
Install inlet temperature sensor (7) to diesel particulate filter canister (1). Refer to Disassembly and Assembly, "Temperature Sensor (DPF) - Remove and Install" for the correct procedure.
Install catalyst inlet temperature sensor (6) to diesel particulate filter canister (1). Refer to Disassembly and Assembly, "Temperature Sensor (Catalyst Inlet) - Remove and Install" for the correct procedure.
Position a new sealing washer (3) (not shown) onto banjo bolt (2).
Install banjo bolt (2) to the tube assembly. Install remaining new sealing washer (3) (not shown) between the tube and diesel particulate filter canister (1). Tighten the banjo bolt hand tight.
Position a new sealing washer (5) (not shown) onto banjo bolt (4).
Install banjo bolt (4) to the tube assembly. Install remaining new sealing washer (5) (not shown) between the tube and diesel particulate filter canister (1). Tighten the banjo bolt hand tight.
Tighten banjo bolt (2) and banjo bolt (4) to a torque of 25 N m (221 lb in).