809725 Mercruiser COVER

Start By:a. remove hood and dust ejectorb. remove engine side guards 1. Drain the coolant from the radiator.
Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping Freon-12 (C C12 F2 Dichloro Difluoro Methane) can cause freezing of human flesh.DO NOT SMOKE WHILE WORKING ON AIR CONDITIONING SYSTEMS. Inhaling Freon-12 through any smoking material, although not toxic or flammable, can generate phosgene gas and cause violent illness. ALSO, HEAT MUST NEVER BE APPLIED TO A CHARGED SYSTEM. See Air Conditioning And Heating Service Manual, Form No. SENR3334,for more information on removal and installation of lines and refrigerant from the system.
2. Remove air conditioning lines (7) from the air conditioning dryer (5).3. Remove clips 94) and (12) from the air conditioning lines.4. Remove two bolts (1), two bolts (6) and two bolts (13).5. Remove air conditioning dryer (5), bracket (8) and cooler core (11). Lay the cooler core (11). Lay the cooler core on the track of the machine. Be careful not to damage the core.6. Remove radiator hose (10).7. Remove clip (2).8. Remove four bolts (3).9. Remove condenser (9) and lay out of the way. 10. Remove four nuts (15) and two bolts (14). Remove support (16). Remove the bolt from the middle of the fan guards.11. Remove six bolts (18). Remove fan guards (17). 12. Remove six bolts (19) and strip (20). Remove radiator baffling (21). 13. Remove two bolts (26). Remove four bolts (23) and two strips (22).14. Remove all bolts (25), except bolt (24).15. Remove shield (27). 16. Remove four bolts (30), two strips (28) and loosen baffling (29). Remove five bolts (31), bracket (33) and shield (34). Do not remove bolt (32). 17. Remove six bolts (35) and plate (36). 18. Remove two clips (37). 19. Fasten tooling (A) and a hoist to the radiator guard as shown. 20. Disconnect elbow (38) from radiator (39). Remove bolt, washer and retainer (40) from both rear pins.
Typical Example21. Install tooling (B) and remove the rear pins.22. Slowly and carefully, tilt the radiator guard and radiator until it stops. The following steps are for tilting the radiator guard and radiator back.23. Fasten tooling (A) and a hoist to the radiator guard. Slowly and carefully, tilt the radiator guard and radiator back into its upright position. Install the rear pins.24. Install the bolt, washer and retainer (40) to both rear pins. Install the two clips (37). Install plate (36) and six bolts (35).25. Install shield (34), bracket (33) and five bolts (31). Install two strips (28), four bolts (30) and tighten baffling (29).26. Install shield (27). Install all of bolts (25). Install the two strips (22), four bolt (23) and two bolts (26).27. Install radiator baffling (21). Install strip (20) and six bolts (19).28. Install fan guards (17) and six bolts (18). Install the bolt in the middle of the fan guards. Install support (16). Install two bolts (14) and four nuts (15).29. Position condenser (9) and install four bolts (3) and clip (2). Connect radiator hose (10).30. Position cooler core (11). Install bracket (8) and air conditioning dryer (5). Install two bolts (13), two bolts (6) and two bolts (1).31. Install clips (12) and (4) on the air conditioning lines. Connect lines (7) to the dryer (5).32. Fill the radiator with coolant to the correct level.33. See the Air Conditioning And Heating Service Manual, Form No. SENR3334 for procedures to purge and add Freon-12 to the system.End By:a. install engine side guardsb. install hood and dust ejectorRemove And Install Radiator Guard And Radiator
Start By:a. tilt radiator and radiator guard 1. Fasten tooling (A) and a hoist to the radiator guard as shown.2. Remove eight bolts (1) and then open grille (2). 3. Disconnect four hoses (3). 4. Cut tie strap (5) and disconnect wiring harness (4). 5. Remove bolts (6), retainer (7) and drive out pins (8) from both sides of the radiator. 6. Remove radiator guard and radiator. Weight of the unit is 1200 Kg (2770 lb.). For installation of the radiator guard and radiator, reverse the procedures of Steps 1 through 6.