22206072 Volvo.Penta Junction box

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.
Illustration 1 g03330736
Remove bolts (2) and bolts (5) from tube assembly (1).
Remove tube assembly (1) from exhaust cooler (NRS) (7) and exhaust gas recirculation valve (4).
Remove gasket (3) (not shown) and gasket (6) (not shown).
Illustration 2 g03330738
Disconnect engine harness assembly (8) from harness assembly (9) for exhaust gas recirculation valve (4).
Remove the bolt from clip (11) for harness assembly (9).
Remove bolts (10) and bolt (15) for bracket (12).
Position bracket (12) away from exhaust gas recirculation valve (4).
Remove bolts (16) from exhaust gas recirculation valve (4). Support the exhaust gas recirculation valve as the bolts are removed.
Remove exhaust gas recirculation valve (4) from the inlet manifold (13).
Remove gasket (14) (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.
Illustration 3 g03330738
Clean the gasket surface of exhaust gas recirculation valve (4) and the gasket surface exhaust gas recirculation valve (4).
Position a new gasket (14) (not shown) onto exhaust gas recirculation valve (4). Ensure that the gasket is correctly orientated.
Apply Tooling (A) to the threads of bolt (15) and bolts (16).
Position exhaust gas recirculation valve (4) onto inlet manifold (13).
Install bolts (16) to exhaust gas recirculation valve (4) hand tight.
Position bracket (12) onto exhaust gas recirculation valve (4).
Install bolts (10) and bolt (15) to bracket (12).
Tighten bolts (15), bolts (16), and bolts (10) to a torque of 25 N m (221 lb in).
Connect engine harness assembly (8) to harness assembly (9) for exhaust gas recirculation valve (4).
Install the bolt for clip (11) for harness assembly (9).
Tighten the bolt for clip (11) to a torque of 25 N m (221 lb in).
Illustration 4 g03330736
Ensure that tube assembly (1) is clean and free from restriction, wear, and damage. If necessary, replace the tube assembly.
Apply Tooling (A) to the threads of bolts (2) and bolts (5).
Position a new gasket (6) (not shown) onto tube assembly (1).
Position tube assembly (1) onto exhaust cooler (NRS) (7).
Loosely install bolts (5) to tube assembly (1).
Position a new gasket (3) (not