808625 Mercruiser CAP, Drive Lube Monitor, Oil Bottle

1. Fasten a hoist to implement pump (1). Remove the bolts that hold pump (1) and remove the pump. The weight of implement pump (1) is 59 kg (130 lb.). 2. Remove tube assembly (3) from the left side of the engine.3. Fasten a hoist to starting motor (4). Disconnect wire assembly (2) from the engine block. Remove the bolts and starting motor (4) from the flywheel housing. The weight of starting motor (4) is 36 kg (80 lb.). 4. Remove the bolts that hold plate (5) in position. Slide plate (5) up and off grommet (6). Remove grommet (6) from the fuel lines.5. Remove firewall (7) from the flywheel housing. 6. Remove yoke (8) and the cover from the pump drive. 7. Use tool (A) and fasten a hoist to pump drive (9). Remove the remainder of the bolts that hold pump drive (9). Pull pump drive (9) and the O-ring seal out of the flywheel housing. The weight of pump drive (9) is 29 kg (65 lb.).8. Follow Step 7 to remove pump drive (10). 9. Disconnect tube assembly (13) from tube assembly (12) and move tube assembly (13) to the side of the engine.10. Remove turbocharger oil line (11) from the engine. 11. Remove the top half of shield assembly (14) from over the turbocharger. Remove shield assembly (18). Loosen the clamps that hold tube assembly (15) to the exhaust manifold and tube assembly (17) to the exhaust manifold elbow. Remove tube assemblies (15) and (17) from the engine.12. Remove air cleaner housing support (16) from the engine. 13. Remove either starting aid tube (21) from the engine.14. Remove the clips that hold fuel lines (22) to bracket (20) and remove bracket (20) from the engine.15. Remove support (19) from the engine. 16. Remove bolts (23) to remove caps (24) and supports (25) from the mount assemblies on each side of the flywheel housing. 17. Remove the mount assemblies and supports (26) from each side of the flywheel housing. 18. Remove cover (27) and the O-ring seal from the flywheel housing. 19. Use tooling (A) and fasten a hoist to flywheel housing (28). Remove the bolts that hold flywheel housing (28) in position. Pull flywheel housing (28) off the dowels and remove it. The weight of flywheel housing (28) is 158 kg (350 lb.).20. Remove bolts (29) from shafts (31).
Bearings (34) can fall out of gears (30) when the gears are removed from the flywheel housing.
21. Remove gears (30) from the flywheel housing.22. Remove shafts (31), bearing cones (32), spacers (33) and bearing cones (34) from gears (30).23. If necessary, remove bearing cups (35), spacers (36) and the snap rings from gears (30). The bearing cups will have damage after removal. Use new parts for replacement.Install Flywheel Housing
1. Install the snap rings in the groove of both idler gears (30).2. Install the spacers for bearing cups (35) in gears (30) from the side that has the part number.