804996 Mercury SPRING

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.
Illustration 1 g06483767
Remove bolts (7) and remove cooler (9) from exhaust gas recirculation valve assembly (1). Ensure that the tube assemblies on the cooler are not strained as the exhaust gas recirculation (EGR) valve assembly is removed.
Remove gasket (5) (not shown) from the cooler (9).
Remove O-ring seal (8) (not shown) from EGR valve assembly (1).
If necessary, remove bolts (3) from EGR valve assembly (1) and remove bracket (4) from the bolts.Note: Note the orientation of the bracket for installation purposes.
If necessary, remove plate (5) from EGR valve assembly (1). Remove gasket (2) from EGR valve assembly (1).Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - International Products P-80 Emulsion Rubber Assembly Lubricant 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.
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Illustration 2 g06483767
Ensure that the gasket surfaces of EGR valve assembly (1) and cooler (3) are clean and free from damage.
Position bracket (4) on to bolts (3) in the orientation noted on removal.
Install plate (5) onto the bolt assembly.
Position new gasket (2) (not shown) onto the bolt assembly, install the bolt assembly to the EGR valve assembly. Tighten the bolts finger tight.
Tighten bolts (3) to a torque of 12 N m (106 lb in).
Install a new gasket (8) to cooler (9).
Use Tooling (A) to lubricate a new O-ring seal (6) (not shown). Install the O-ring seal to exhaust gas recirculation valve assembly (1).
Install cooler (9) to EGR valve assembly (1). Ensure that the tube assemblies on the cooler are not strained as the exhaust gas recirculation valve assembly is installed.
Install bolts (7) to exhaust gas recirculation valve assembly (1). Hand tighten the bolts.
Install the exhaust cooler for the NOx Reduction System (NRS) Disassembly and Assembly, Exhaust Cooler (NRS) - Remove and Install for the correct procedure.
After the installations of the exhaust cooler assembly, tighten bolts (7) to a torque of 22 N m (195 lb in). Ensure that the tube assemblies of the exhaust cooler are not strained as the bolts are tightened.