Mercury MerCruiser D2.8L D-Tronic Service Manual page 773

SERVICE MANUAL NUMBER 22
22. Remove hex nuts retaining intercooler housing flanges to exhaust / intake manifold
studs.
Typical
Remove ALL washers from studs BEFORE lifting off intercooler and intercooler
housing. Do NOT drop anything into intake ports or severe engine damage could
occur.
23. Using a magnet to remove all lockwashers from studs where hex nuts were removed.
24. Remove intercooler and housing.
Disassembly
Whenever intercooler is disassembled or radiator insert removed from intercooler
ALL O-ring seals must be replaced to prevent seawater from leaking into intake air
duct and manifold which could result in severe engine damage.
1. Remove intake duct from rear of intercooler.
D4.2L Shown (D2.8L Similar)
90-860074--1 FEBRUARY 2002
a
c
b
a - Intercooler/Intercooler Housing
b - Exhaust/Intake Manifold
c - Hex Nuts
a - Intercooler Housing (Side Intake Duct on D2.8L)
b - Intake Duct
a
70916
CAUTION
CAUTION
a
b
INTERCOOLER
c
70921
70931
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