808525A03 Mercury DECAL SET

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.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Turn the battery disconnect switch to the OFF position.
Illustration 1 g06451609
Illustration 2 g06451649
Disconnect engine harness assembly (6) for Exhaust Gas Recirculation (EGR) valve (5).
Protect starter motor (7) and the engine harness from coolant when EGR valve (5) is removed.
Reposition hose clamp (12) and disconnect hose (11) from EGR valve (5).
Remove bolts (10) from EGR valve (5).
Remove bolts (4) from EGR valve (5). Support the EGR valve as the bolts are removed.
Remove EGR valve (5) from exhaust gas cooler (NRS) (9) and exhaust manifold (3).
Remove gasket (1) (not shown) and gasket (2) (not shown).
Remove O-ring seal (8) (not shown).Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Anti-Seize Compound 1
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.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Inspect inside the exhaust gas recirculation valve for deposits or debris. Use a suitable clean lint free cloth with a suitable engine cleaner to clean inside the exhaust gas recirculation valve.
Illustration 3 g06451609
Illustration 4 g06451649
Clean the gasket surfaces of exhaust gas recirculation valve (5).
Install new O-ring seal (8) to EGR valve (5)
Apply Tooling (A) to bolts (4) and bolts (10).
Position new gasket (1) (not shown) and new gasket (2) (not shown) onto exhaust gas recirculation valve (5). Ensure that the gaskets are correctly orientated.
Position exhaust gas recirculation valve (5) onto exhaust manifold (3) and exhaust gas cooler (NRS) (9).
Install bolts (4) and bolts (10) finger tight.Tighten bolts (4) to a torque of 22 N m (194.72 lb in)Tighten bolts (10) to a torque of 11 N m (97.36 lb in)
Install hose (11) onto EGR valve (5).
Slide hose clamp (12) into position and tighten the hose clamp securely.
Connect harness assembly (6) to EGR valve (5).
Ensure that starter motor (7) and the engine wiring harness assembly is dry.
Turn the battery disconnect switch to the ON position.
After replacement of the exhaust gas recirculation valve, the exhaust gas recirculation valve must be