803755007 Mariner TUBE, Water

At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gage to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
1. Release the pressure in the cooling system by slowly loosening the filler cap on the radiator. Drain the coolant from the radiator to a level below the aftercooler, in a suitable container for storage or disposal. 2. Remove two clips (1) that secure turbocharger coolant tubes (2) to muffler group frame (3). 3. Remove muffler clamp (5) that fastens muffler (4) to turbocharger (6). 4. Support muffler group (7) with hoist and a suitable lifting device. Remove two bolts (8) and the washers. 5. Remove four bolts (9), the washers and nuts that fasten muffler group to the after cooler. 6. Remove six bolts (10) and the washers that fasten the muffler group to air cleaner support brackets (11). Remove muffler group. The weight of the muffler group is 145 kg (320 lb). 7. Disconnect fuel lines from relief valve (12). Cap and plug any open connection.8. Remove bolt (13) and the washer. Remove bolt (14), the washer, clip and spacer. Remove elbow (15). 9. Disconnect either starting aid tube assembly (16) from the top of after cooler assembly.10. Disconnect input tubes (17) from each side of aftercooler assembly. It is not necessary to remove input tubes from the turbochargers. 11. Remove twenty four bolts (18) and the washers that fasten aftercooler cover (19) to the aftercooler housing. Place the wiring harness, clips and brackets aside.12. Remove aftercooler cover (19) and the gasket (not shown). 13. Remove two bolts (23), elbow (22) and the O-ring seal.14. Remove two adapters (20) and the O-ring seal (21).15. Remove two adapters (24) and O-ring seal. 16. Remove eight bolts (25) and washers. 17. Carefully remove aftercooler core (26) with suitable hoist. The weight of the aftercooler core is 27 kg (60 lb).18. Remove the O-ring seals from the aftercooler core. 19. Remove two bolts (28) and the washers (rear side of the aftercooler). 20. Remove twelve bolts (29) and the washers. Remove aftercooler housing (30) and the gasket (not shown). The following steps are for the installation of the aftercooler and aftercooler core. 21. Install a new gasket (not shown) prior to installation of aftercooler housing (30).22. Carefully install aftercooler housing (30). Install twelve bolts (29) and the washers. Tighten bolts (29) to a torque of 47 9 N m (35 7 lb ft). 23. Install two bolts (28) and the washers. Tighten bolts (28) to a torque of 47 9 N m (35 7 lb ft). 24. Install the O-ring seals on the aftercooler core. Lubricate O-ring seals and their mating bores with glycerin.25. Carefully install aftercooler core (26). 26. Install eight bolts (25) and the washers. Tighten bolts (25) to a torque of 25 6 N m (18 4 lb ft) 27. Install adapters (24). Install O-ring seal (not shown), elbow (22), and two bolts (23).28. Install adapters (20) and O-ring seal (21). 29. Install a new gasket (not shown) and aftercooler cover (19). Install twenty four bolts and washers (18). Tighten to a torque of 47 9 N m (35 7 lb ft). 30. Connect input tubes (17) and either aid tube (16) to aftercooler cover.31. Connect either starting aid tube assembly (16) to the top of aftercooler cover. 32. Install elbow (15). Fasten elbow to aftercooler assembly with bolt (13) and bolt (14), the washer clip and spacer.33. Connect two fuel lines to relief valve (12). 34. Install muffler group (7). Install two bolts (8) and washers. 35. Fasten muffler group to aftercooler assembly with four bolts (9), the washers and nuts. 36. Fasten the rear portion of the muffler group to air cleaner support brackets (11) with six bolts (10). 37. Fasten muffler (4) to turbocharger (6) with clamp (5). 38. Install two clips (1) to fasten turbocharger coolant tubes (2) to muffler group frame (3). Refer to the Operation & Maintenance Manual for all fluid capacities and the proper filling procedures.End By:a. install hood group