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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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Ensure that the wiring harness is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting. |
- Ensure that the NRS exhaust cooler is clean and free from restriction. Ensure that the NRS exhaust cooler and associated pipework is free from wear and damage. If necessary, replace any components that are worn or damaged.
Note: The NRS exhaust cooler must not be disassembled. The internal components of the NRS exhaust cooler should not be cleaned.
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Illustration 1 g02415876 - Position the NRS exhaust cooler onto the cylinder block. Install bolts (29) and bolts (30) hand tight.
Note: The bolts used to secure the NRS exhaust cooler to the cylinder block are different lengths. The NRS exhaust cooler should be supported as the bolts are installed.
- Tighten bolts (29) and bolts (30) to a torque of
44 N·m (33 lb ft) - Position new gasket (24) (not shown) and new gasket (27) (not shown) onto tube assembly (28).
- Position tube assembly (28) onto NRS exhaust cooler (17). Install new bolts (26) and tighten the bolts ensuring that the tube assembly can move freely.
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Illustration 2 g02415956 - Install the turbocharger and the exhaust manifold as an assembly. Refer to Disassembly and Assembly, "Exhaust Manifold and Turbocharger - Install" for the correct procedure.
- Install new bolts (25) and tighten the bolts ensuring that the tube assembly can move freely.
- Tighten bolts (25) and bolts (26) to a torque of
22 N·m (195 lb in) - Position new gasket (19) (not shown) and new gasket (23) (not shown) onto tube assembly (21)
- Position tube assembly (21) onto the NRS exhaust cooler and the cylinder head. Install bolts (18) and bolts (20) hand tight.
- Tighten bolts (18) to a torque of
22 N·m (195 lb in) .Tighten bolts (20) to a torque of
18 N·m (159 lb in) .Note: Ensure that the tube assembly is not stressed as the bolts are tightened.
- Install a new cable strap (22).
Note: Ensure that the cable strap meets Original Equipment Manufacturers (OEM) specifications.
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Illustration 3 g02415996 - Position a new gasket (3) (not shown) onto the induction mixer.
Note: Ensure that the gasket is correctly installed onto the locating dowels in the induction mixer.
- Position a new gasket (10) (not shown) onto tube assembly (8).
- Position tube assembly (8) between the bracket and the induction mixer chamber and the NRS exhaust cooler.
- Install bolts (4) and bolts (9). Tighten the bolts to a torque of
18 N·m (159 lb in) Note: Ensure that the tube assembly is not stressed as the bolts are tightened.
- Tighten bolts (1) to a torque of
44 N·m (33 lb ft) - Install new gasket (7) and new gasket (16) to tube assembly (5). Position the tube assembly onto the cylinder head and NRS exhaust cooler (17).
- Install bolts (6) and bolts (11) finger tight.
- Tighten bolts (6) to a torque of
22 N·m (195 lb in) Tighten bolts (11) to a torque of
18 N·m (159 lb in) Note: Ensure that the tube assembly is not stressed as the bolts are tightened.
- Position hose clamp (15) onto hose assembly (14). Install the hose assembly to the turbocharger outlet and tighten the hose clamp securely.
- Position hose clamp (13) onto hose assembly (12). Install the hose assembly to the turbocharger inlet and tighten the hose clamp securely.
- Install the exhaust back pressure valve. Refer to Disassembly and Assembly, "Exhaust Back Pressure Valve - Remove and Install" for the correct procedure.
- Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.
