3R4Q87801-1 Tohatsu 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.
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Remove turbocharger oil drain pipe (11). Refer to Disassembly and Assembly, Turbocharger - Remove for the correct procedure.
Loosen hose clamp (6) and disconnect hose (5) from exhaust cooler (NRS) (7).
Loosen hose clamp (8) and disconnect hose (9) from exhaust cooler NRS) (7).
Remove bolts (2) from tube assembly (3).
Loosen hose clamp (13) and disconnect tube assembly (3) from hose (14).
Remove tube assembly (3) from exhaust cooler (NRS) (7).
Remove O-ring (1) (not shown) from tube assembly (3).
Follow Step 8.a through Step 8.b to remove hose (5) and hose (9).
Loosen hose clamp (4) and remove hose (5) from tube assembly (3).
Loosen hose clamp (10) and remove hose (9) from tube assembly (3).
If necessary, loosen clamp (15) and remove hose (14) from the water pump.
Remove tube assembly (12). Refer to Disassembly and Assembly, Exhaust Gas Recirculation Valve - Remove and Install for the correct procedure.
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Remove bolt (16) from the exhaust cooler (NRS) assembly (7).
Remove bolts (18) from the exhaust manifold (19) and remove the exhaust cooler (NRS) assembly.Note: Support exhaust cooler (NRS) assembly as the bolts are removed.
Remove gasket (17) (not shown) from between exhaust manifold (19) and exhaust cooler (NRS) assembly (7).
If necessary, remove bolt (20) from bracket (21).
Plug and cap all open ports on exhaust cooler (NRS) assembly (7).Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-5598 Anti-Seize Compound 1
Check all components for wear and damage. If necessary, replace any components that are worn or damaged.
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Ensure that the exhaust cooler (NRS) assembly is free from restriction and external damage. Ensure that the exhaust cooler (NRS) assembly and tube assemblies are free from wear and damage. Refer to Systems Operation Testing and Adjusting, "Exhaust Cooler (NRS) - Test" for the correct inspection procedure.Note: Cleaning of the internal core of the exhaust cooler (NRS) should not be carried out.
Clean the gasket surfaces of exhaust cooler (NRS) assembly (7) and exhaust manifold (19).
If necessary, position bracket (21) onto exhaust cooler (NRS) assembly (7). Ensure that the bracket is correctly orientated and loosely install bolt (16).
Apply Tooling (A) to the threads of bolts (18).
Install bolts (18) to exhaust manifold (19).
Position gasket (17) (not shown) onto bolts (18).
Remove plug and cap from all open ports of exhaust cooler (NRS) assembly (7)
Position exhaust cooler (NRS) assembly (7) onto exhaust manifold (19) and tighten bolts (18) finger tight. Support the exhaust cooler (NRS) assembly as the bolts are tightened.
If necessary, install bolt (20) to bracket (21).
Tighten bolts (18) to a torque of 25 N m (221 lb in).
Tighten bolt (16) to a torque of 25 N m (221 lb in).
Tighten bolt (20) to a torque of 25 N m (221 lb in). Ensure that bracket (21) is not strained as the bolt is tightened.
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Install tube assembly (12). Refer to Disassembly and Assembly, Exhaust Gas Recirculation Valve - Remove and Install for the correct procedure.
Install new O-ring (1) (not shown) to tube assembly (3).
If necessary, position hose clamp (15) onto hose (14). Install hose assembly (14) to the water pump and tighten hose clamp (15) securely.
Position hose clamp (4) and hose clamp (