10104J60 Mariner OWNERS MANUAL, 9.9/15 (2-Stroke) (2006)

Removing The Engine
INADVERTENT STARTING OF THE ENGINE CAN CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH.
1. Set the battery switch at "Off" and disconnect the battery ground (-) cable from the battery. 2. Open the drain valve and drain the fuel tank. 3. Remove the air stack extension and muffler. Cover the openings in the air cleaner and the engine. 4. Remove the upper radiator grill and upper pump cowling.5. Unbolt and remove as a unit the radiator cowling, engine cowling and front and rear pump cowling. 6. Remove the ducting from between the engine and the air cleaner, then cover the openings in the engine and air cleaner.7. Unbolt the mounting bracket from the engine, then remove the air cleaner and mounting bracket.8. On machines 504109 through 504113, remove the radiator support bracket from between the engine and the radiator.
MACHINES 504114 & SUBSEQUENT
MACHINES 504122 & SUBSEQUENT9. On machines 504114 and subsequent, remove the radiator mount support.10. On machines 504122 and subsequent, remove the fan guard.11. Drain the radiator, then remove the upper and lower hoses from between the engine and radiator. 12. Relieve the accessory pump drive belt tension, then remove the belt.13. Repeat step 12 for the water pump drive belt. 14. Close the shutoff valves in the pump supply lines. 15. If the machine is not equipped with an auxiliary cutter, skip this step and step 16. Otherwise, thoroughly clean around the auxiliary cutter drive pump and hose connections, then disconnect the hoses from the pump. Cap or plug all openings immediately.16. Attach a lifting device to the auxiliary cutter drive pump, remove the mounting bolts, move the pump straight back until the pump shaft is clear of the gearbox, then move the pump away.17. Thoroughly clean around the wheel drive pump and hose connections, then disconnect the hoses from the pump. Cap or plug all openings immediately. 18. Disconnect the wheel drive pump control cable mounting bracket and cable from the pump and lay them aside where they will not be damaged. DO NOT ALTER THE CONTROL CABLE ADJUSTMENT.19. Attach a lifting device to the wheel drive pump, remove the mounting bolts, move the pump straight back until the pump shaft is clear of the gearbox, then move the pump away.20. Remove the cutter drive shaft (see Cutter 3.0-11). 21. Disconnect the throttle cable and lay it aside where it will not interfere with engine removal.22. Disconnect the fuel supply and return hoses from the engine.23. Mark for identification during reassembly, then disconnect all wiring harness wires from the terminals at the following engine components: a. Starter.b. Fuel solenoid.c. Oil pressure sender.d. Oil pressure switch.e. Water temperature sender.f. Alternator.g. Hour meter.24. Check the engine over to be sure all wires, cables and hydraulic lines which would interfere with engine removal have been disconnected. 25. Attach a lifting device to the engine and take enough of a strain in the lifting lines to support the engine.26. Remove the bolts which hold the rear mount bracket to the cutter slide assembly and the front of the engine to either the radiator and oil cooler bracket or the water pump mounting bracket.27. Lift the engine straight up and away.Building The Engine Up
The simplest way to build up a new engine is to position the new engine beside the old one and properly support both so they can safely be worked on. Then remove one component at a time from the old engine and install it on the new engine until all required components have been transferred to the new engine. Components that may have to be transferred include: 1. The pump drive gearbox. See page 4.0-2 for removal and installation procedures.2. The throttle bracket.3. The engine oil pressure switch and sender.4. The water temperature sender.5. The hour meter and bracket.Installing The Engine
1. Check that the mounting area on the machine is clear of all hoses, wires, control cables, etc.
MACHINES 504114 & SUBSEQUENT2. Attach a lifting device to the engine.3. Move the engine into position on the cutter slide assembly and install the mounting bolts.4. Install the cutter drive shaft (see Cutter 3.0-16).5. Attach a lifting device to the wheel drive pump, move the pump into position on the pump drive gearbox, then install the mounting bolts.6. If the machine is equipped with an auxiliary cutter, repeat step 5 for the auxiliary cutter drive pump.7. Thoroughly clean around the pump ports and hose connections, then connect the hoses to the pumps.8. Install the upper and lower radiator hoses.9. On machines 504122 and subsequent, install the fan guard.10. On machines 504114 and subsequent, install the radiator mount support. On machines 504109 through 504113, install the radiator support bracket (see page 2.1-2) 11. Connect the wiring harness wires to the terminals at the following components: a. Starter.b. Fuel solenoid.c. Oil pressure sender.d. Oil pressure switche. Water temperature sender.f. Alternator.g. Hour meter. 12. Connect the throttle cable.13. Connect the fuel supply and return lines to the engine.
ENGINE AIR INTAKE AND EXHAUST SYSTEM (504109 THROUGH 504113)
ENGINE AIR INTAKE AND EXHAUST SYSTEM (504113 AND SUBSEQUENT)14. Install the air cleaner and mounting bracket on the engine, then install the ducting between the engine and the air cleaner.15. Install the water pump and accessory pump drive belts and adjust the belt tension (see Miscellaneous 1.0-11 and Hydraulics - Accessory 3.0-2). 16. Open the shutoff valves in the pump supply lines, loosen the supply hose connection at each pump until air-free hydraulic oil flows from the connection, then tighten the connection.
THE SUPPLY HOSE TO EACH PUMP MUST BE FILLED WITH HYDRAULIC OIL BEFORE STARTING THE ENGINE OR THE PUMP WILL BE DAMAGED.
17. Fill the wheel drive pump case through the uppermost case drain port with filtered hydraulic oil. 18. Connect the control cable mounting bracket and cable to the wheel drive pump.19. Check the oil level in the hydraulic oil tank. Transfer oil from the reple