808675 Mercruiser CLIP, Spring

Start By:a. remove counterweight **This operation is in the 307 Excavator Machine Systems Disassembly & Assembly module, SENR6199.1. Close the fuel tank supply valve if so equipped.
At operating temperature, the hydraulic oil is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the implement hydraulic circuits (boom, stick and bucket) before any hydraulic lines or components are disconnected or removed.
2. Release the pressure in the hydraulic system as follows:a. Lower the blade to the ground.b. Fully retract the rod in the stick cylinder.c. Adjust the position of the bucket so it will be flat on the ground when the boom is lowered.d. Lower the boom until the bucket is flat on the ground.e. Shut off the engine, and put the hydraulic activation control lever in the "Lock" position.f. Move the control levers for the boom, bucket, stick and swing through their full travel strokes. This will relieve any pressure that may be present in the pilot system.g. Slowly loosen the Fill/Vent plug on the hydraulic oil tank to release the pressure.h. Tighten the Fill/vent plug on the hydraulic oil tank.i. The pressure in the hydraulic system has now been released. Lines and components can now be removed.3. Remove the plug from the bottom of the hydraulic oil tank. Install the ecology drain valve to drain the oil from the hydraulic oil tank. Drain the oil into a suitable container for storage or disposal. The capacity of the hydraulic oil tank is 57 liters (14.8 U.S. gal).
At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure in the cooling system. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
4. Drain the coolant from the cooling system into a suitable container for storage or disposal. The capacity of the cooling system is 14.6 liters (3.8 U.S. gal) 5. Loosen two clamps (1), and remove upper radiator hose (2). 6. Loosen two bolts (5). Remove three bolts (3) that hold the upper fan guard in position. Remove upper fan guard (4). 7. Remove three bolts (7). Remove lower fan guard (6). 8. Loosen clamp (8). Disconnect lower radiator hose (9) from the radiator. 9. Put identification marks on the two heater hoses for installation purposes. Disconnect two heater hoses (10) and (11) at the water temperature regulator housing. Remove clip (12). Move the heater hoses clear of the engine. 10. Remove clip (15). Put identification marks on the three fuel hoses for installation purposes. Disconnect three hoses (13), (14) and (16) at the fuel system. 11. Remove bolt (18) and cover (17) from over the left front engine mount. 12. Remove two bolts (19) to disconnect linkage (20) from the fuel system.13. Remove two bolts (22), and remove bracket (21). Move the linkage away from the engine. 14. Remove clip (23). Remove tie (25). Disconnect wiring harness (24) at the fuel shutoff solenoid and the sensor.15. Put identification marks on the wires connected to the electric starting motor for installation purposes. Disconnect battery cable (26). Remove bolt (27) and the washer. Remove bracket (28). Move wiring harness (24) away from the engine. 16. Remove four bolts (30) and exhaust pipe extension (29). 17. Remove five bolts (31) and the washers. Open the right rear access door, and remove three bolts (33) and the washers. Remove sheet assembly (32) and upper sheet assembly (34). 18. Remove four bolts (36), the washers and shims that hold right rear access door (35) in position. Remove the access door. 19. Put identification marks on nine hose assemblies (37) and one tube assembly (38) that are connected to the main hydraulic pump and pilot pump. Disconnect the hose assemblies and tube assembly. Put plugs in the hose assemblies to keep dirt out of the hydraulic system. 20. Remove five bolts (39), the washers and upper sheet (34). 21. Remove three bolts (40), the washers and lower sheet assemblies (41) and (42). 22. Disconnect wire (45) and wires (46) at the main water inlet. Remove clip (43). Reinstall bolt (44) in the lifting bracket. 23. Remove clips (48) and (50). Put identification marks on all wires (49) that are connected to the back side of the alternator for installation purposes. Disconnect the wires from the back side of the alternator. Disconnect two connectors (47).
View From Under Machine24. Remove six bolts (51), the washers and sheet assembly (52) from under the engine.
View From Under Machine25. Disconnect ground wire (53) from the right rear engine mounting bracket.
View From Under Machine26. Remove clip (54). Move wiring harness (55) out of the way of the engine. 27. Remove four engine mounting bolts (56), the washers and support assemblies that hold the engine to the frame.
The front and rear upper and lower rubber engine mounts have different part numbers. The rubber mounts must not be mixed. After removal of the engine and main hydraulic pump, put identification marks on the rubber mounts as to their location.
28. Remove four upper rubber mounts (57). Lower rubber mounts (58) will be removed after the engine has been removed from the machine. 29. Remove six bolts (60) and the washers that hold fan shroud (59) to the radiator. Mount the fan shroud toward the front of the engine. Hang the fan shroud on the fan assembly. 30. Remove clamp (61) and breather hose (62).
Do not damage the radiator core during removal of the engine. The engine must be held level during removal to prevent possible interference between components.
31. Fasten Tool (A) and a hoist to the engine as shown. Remove engine (63) and the main hydraulic pump as a unit. The weight of the unit is 454 kg (1000 lb).32. Rem