860454 Volvo.Penta Pulley

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 g06102111
Typical example
Illustration 2 g06102122
Typical example
Disconnect harness assembly (1) from exhaust gas recirculation valve (2).
Remove bolts (3) from tube assembly (5). Support the exhaust gas recirculation valve as bolts (3) are removed.
Remove exhaust gas recirculation valve (2) from the inlet manifold.
Remove gasket (4) (not shown) and gasket (9) (not shown).
If necessary, remove bolts (6) and remove tube assembly (5) from exhaust cooler (NRS) (7) and exhaust gas recirculation valve (2).
Remove gasket (8) (not shown).Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-5598 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.
Inspect the airways of the exhaust gas recirculation valve for deposits and debris. Use a suitable clean lint free cloth with a suitable engine cleaner to clean the deposits and debris out of the exhaust gas recirculation valve.
Illustration 3 g06102111
Typical example
Illustration 4 g06102122
Typical example
Clean the gasket surface's of exhaust gas recirculation valve (2).
Ensure that tube assembly (5) is clean and free from restriction, wear, and damage. If necessary, replace the tube assembly.
Position a new gasket (9) (not shown) onto exhaust gas recirculation valve (2). Ensure that the gasket is correctly orientated.
Position exhaust gas recirculation valve (2) onto the inlet manifold.
Position a new gasket (4) (not shown) between tube assembly (5) and exhaust gas recirculation valve (2).
Apply Tooling (A) to the threads of bolts (3).
Position tube assembly (5) onto exhaust cooler (NRS) (7).
Loosely install bolts (3) to tube assembly (5).
Position a new gasket (8) (not shown) onto tube assembly (5).
Position tube assembly (1) onto exhaust cooler (NRS) (7).
Apply Tooling (A) to the threads bolts (6).
Loosely install bolts (6) to tube assembly (5).
Tighten bolts (3) and bolts (6) to a torque of 25 N m (221 lb in). Ensure that tube assembly (5) is not strained as the bolts are tightened.
Connect harness assembly (1) to exhaust gas recirculation valve (2).
After replacement of the exh