808207 Mercruiser BOLT

Release the pressure in the cooling system by slowly loosening the filler cap on the radiator. Drain the coolant from the radiator and oil from the hydraulic oil cooler.1. Drain the coolant from the cooling system.2. Drain the oil from the hydraulic tank to a level below the bottom of the hydraulic oil cooler. 3. Secure grill with straps and hoist. Remove bolts and washers (1) and remove grill (2). Weight of the grill is 136 kg (300 lb). 4. Remove bolts and washers (3). Secure with straps and hoist and remove cover (4). 5. Secure plate with jack or suitable lifting device. Remove bolts and washers (5) and remove plate (6) under radiator. 6. Remove bolts and washers (7) and disconnect bottom radiator hose (8). Remove clip (9) on small hose (10). 7. Remove bolts and washers (11) and move return valve (12) out of away from radiator. 8. Remove handle (13) on fuel supply cable and pull through frame. 9. Disconnect cable (14) on top of injection pump, take cable with guard. 10. Remove bolts and washers (15) and remove door (16). Repeat on other side. 11. Remove bolts and washers (17) and remove plate (18). Evacuate the system.
Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publication SENR3334-01, SENR5664 and NEDG5065-01 for the proper procedure, equipment and tools to reclaim refrigerant from any Caterpillar machine.
Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping refrigerant R-13 (C C12 F2 Dichloro Difluoro Methane) and refrigerant R-134A can cause freezing of human flesh. Do not smoke while working on air conditioning. Inhaling Refrigerant R-12 or R-134A through any smoking material, although not toxic or flammable, can cause violent illness. Also heat must never be applied to a charged system. See Air Conditioning And Heating Service Manual Form No. SENR3334-01 and SENR5664, for more information on removal and installation of lines and refrigerant from the system.
Release the refrigerant R-12 from the system. See Air Conditioning And Heating, Purging The System, Form No. SENR3334-01. 12. Disconnect two air conditioner lines (19). 13. Remove two bolts (20) and pull hose (21) away from radiator guard. Disconnect clamps and pull hose free from radiator guard. 14. Disconnect two hydraulic lines (22) on top, disconnect two water lines (23). 15. Disconnect bottom radiator hose (24), disconnect two hydraulic lines (25) on bottom. Remove bolt on bracket, on small hose. 16. Disconnect two large lines and one small line (26) on fan motor. Remove two bolts and washers and remove terminal (27). 17. Disconnect wiring harness (28). 18. Remove bolt that holds bracket (29). 19. Secure radiator guard with straps and hoist as shown. 20. Remove three bolts and washers (30) on all four sides. Remove radiator guard. The weight of the guard is 1589 kg (3500 lb). Install in the reverse order. See Air Conditioning And Heating Service Manual, Form No. SENR3334 for the correct procedure to charge the system.21. Fill the hydraulic tank with oil to the correct level. For correct level see the Operation & Maintenance Manual.