889740A02 Mercury HANDLE KIT

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 g03350582
If necessary, follow Step 2.a through Step 2.f in order to assemble diesel particulate filter canister (1).
Clean the gasket surfaces of end cap (16), diesel particulate filter (19), and diesel particulate filter canister (23).
Position a new gasket (20) onto canister (23). Ensure that the holes in the gasket are correctly aligned with the canister.
Install diesel particulate filter (19) to canister (23). Ensure that the temporary marks are aligned.
Position a new gasket (18) onto diesel particulate filter (19). Ensure that the holes in the gasket are correctly aligned with the diesel particulate filter.
Install end cap (16) to diesel particulate filter (19). Ensure that the temporary marks are aligned and that the holes in the gasket are correctly aligned with the end cap.
Install bolts (17) and nuts (22) hand tight. Tighten the nuts and bolts to a torque of 15 N m (133 lb in).
Illustration 2 g03351020
Install diesel particulate filter canister (1) onto the mounting bracket.
Install bracket (11) onto diesel particulate filter canister (1). Install the nuts and bolts (12) to bracket (11). 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.
Install bracket (13) onto diesel particulate filter canister (1). Install the nuts and bolts (14) to bracket (13). 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.
Install flexible exhaust pipe (10). Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure. Note: Installation of the flexible exhaust pipe will assist with the alignment of the diesel particulate filter canister.
Tighten the nuts and bolt (12) and nuts and bolt (14) 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.
Connect harness assembly (7).
Install the nut and bolt (15) to the clip for harness assembly (7). Tighten the nuts and bolt (15) to a torque of 10 N m (89 lb in).
Position a new sealing washer (5) (not shown) onto banjo bolt (6).
Install banjo bolt (6) to the tube assembly and diesel particulate filter canister (1). Install remaining new sealing washer (5) (not shown) between the tube and diesel particulate filter canister (1). Tighten the banjo bolt hand tight.
Position a new sealing washer (9) (not shown) onto banjo bolt (8).
Install banjo bolt (8) to the tube assembly and diesel particulate filter canister (1). Install remaining new sealing washer (9) (not shown) between the tube and diesel particulate filter canister (1). Tighten the banjo bolt hand tight.
Tighten banjo bolt (6) and banjo bolt (8) to a torque of 25 N m (221 lb in).
Illustration 3 g03350481
Install catalyst inlet temperature sensor (4) to diesel particulate filter canister (1). Refer to Disassembly and Assembly, "Temperature Sensor (Catalyst Inlet) - Remove and Install" for the correct procedure.
Install inlet temperature sensor (3) to diesel particulate filter canister (1). Refer to Disassembly and Assembly, "Temperature Sensor (DPF) - Remove and Install" for the correct procedure.
Install outlet temperature sensor (2) to diesel particulate filter canister (1). Refer to Disassembly and Assembly, "Temperature Sensor (DPF) - Remove and Install" for the correct procedure.