3801676 Volvo.Penta Longblock, exch

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.
Note: Plug or cap all open ports with new plugs or caps.
If necessary, remove the diesel particulate filter mounting bracket. Refer to Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedure.
Illustration 1 g02717244
Position hose clamp (3) away from the coolant inlet in Position (A). Disconnect hose (4) from exhaust cooler assembly (2).
Reposition hose clamp (7) and hose clamp (10) in order to allow removal of hose (8). Disconnect hose (8) from exhaust cooler assembly (2).
Loosen V-band clamp (9) and position the clamp away from the Exhaust Gas Recirculation (EGR) valve assembly (1).
Remove bolts (5) from exhaust cooler assembly (2). Note: If studs are installed, it will be necessary to remove the studs.
Remove exhaust cooler assembly (2) from the induction manifold.
Remove gasket (6).
Remove clamp (9) from the exhaust cooler assembly. Installation Procedure
Check all components for wear and damage. If necessary, replace any components that are worn or damaged. Note: Remove plugs and caps that were previously installed prior to assembly.
Illustration 2 g02717358
Ensure that the NRS exhaust cooler is free from restriction and external damage. Ensure that the NRS exhaust cooler 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: The NRS exhaust cooler should not be internally cleaned.
Check that the sealing face on the EGR valve assembly (1) and the diffuser is clean and free from damage.
Install a new clamp (9) to NRS mixer chamber (1). Note: Ensure that the clamp is correctly orientated to prevent contact with any other engine components.
Position a new gasket (6) onto the induction manifold.
Position exhaust cooler assembly (2) onto the induction manifold. Install bolts (5) finger tight. If studs were installed instead of bolts, install the studs. Tighten the studs to a torque of 10 N m (89 lb in) Note: Ensure that the exhaust cooler assembly (2) can still move freely.
Tighten clamp (9) to a torque of 10 N m (89 lb in)
Tighten bolts (5) to a torque of 25 N m (221 lb in)
Connect hose (4) to exhaust cooler assembly (2) in Position (A). Position hose clamp (3) onto the coolant inlet.
Install hose assembly (8) to exhaust cooler assembly (2). Position hose clamp (7) and position hose clamp (10) and tighten securely.
If necessary, install the diesel particulate filter mounting bracket. Refer to Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedure. End By:
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.