805759A 5 Mercruiser CAP ASSEMBLY

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     140-7742     Sleeve     2    
B     138-7574     Link Bracket     2    Start By:
Remove the hood. Refer to Disassembly and Assembly, "Hood - Remove".
Remove the blower fan and the fan guard. Refer to Disassembly and Assembly, "Blower Fan and Fan Guard - Remove".
Remove the power train oil cooler. Refer to Disassembly and Assembly, "Power Train Oil Cooler - Remove and Install".Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.Note: Put identification marks on all lines, on all hoses, on all harness assemblies, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Personal injury can result from hydraulic oil pressure and hot oil.Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.
Personal injury can result from hot coolant, steam and alkali.At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand.Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.
Illustration 1 g01262060
Disconnect hoses (1) and (2) .
Disconnect hose assemblies (3) .
Illustration 2 g01262075
Disconnect hose (4) .
Illustration 3 g01263178
Attach Tooling (A) and a suitable lifting device to radiator guard (5). The weight of radiator guard (5) is approximately 159 kg (350 lb).
Remove bolts (7), pin assemblies (6) and radiator guard (5) .
Illustration 4 g01262229
Illustration 5 g01262050
Attach Tooling (B) and a suitable lifting device to cooling system package (8). The weight of cooling system package (8) is approximately 272 kg (600 lb).
Disconnect harness assembly (9) and remove cable strap (10) .
Remove bolts (11) .
Use Tooling (B) and the suitable lifting device in order to remove cooling system package (8) .