95355A1 Mercruiser DOWN PRESSURE RELIEF VALVE KIT (REPAIR KIT)

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Loctite C5-A Copper Anti-Sieze Lubricant -
The Power Train Electric Drive System and the Accessory Power System will contain hazardous voltage levels during machine operation and for a period of time after machine shutdown.Do not remove any covers that will expose energized electrical components while the engine is operating. Do not remove any covers that will expose the energized electrical components while the components remain energized following an engine shutdown.Do not perform any type of electrical maintenance on the orange hazardous voltage conductors, the power train components or the accessory power system components while the engine is operating.Do not perform any type of electrical maintenance on the orange hazardous voltage conductors, the power train components or the accessory power system components while the components remain energized following an engine shutdown.Always perform the safe shutdown and de-energizing procedure before performing electrical service on the Power Train Electric Drive System or the Accessory Power System.Failure to follow these instructions could result in personal injury or death.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
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.
Prepare the machine for maintenance. Refer to Operation and Maintenance Manual , "Prepare the Machine for Maintenance".
Shutdown and de-energizing the machine. Refer to Operation and Maintenance Manual, "Electrical Shutdown and Voltage Discharge".
Release the system pressure. Refer to Operation and Maintenance Manual, "System Pressure Release".
Drain the coolant to a level below the component being removed. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedure.
Illustration 1 g03737673
Open hood panels (1).
Illustration 2 g03737720
Disconnect V-band clamp (2) and tube (3). Loosen clamps (4) and disconnect hose (5).
Illustration 3 g03738039
Disconnect hose assemblies (6)
Illustration 4 g03738046
Disconnect V-band clamp (7) and bellows (8). Disconnect V-band clamp (9) and bellows (10).
Illustration 5 g03738104
Disconnect hose assemblies (11).
Illustration 6 g03738138
Do not step on the turbochargers. Doing so can damage the turbocharger and shorten the turbocharger life.
If the turbine housing or the compressor housing must be rotated to remove the turbocharger, loosen the V-band clamp only enough to allow for rotation (typically 7-10 turns). If the V-band clamp is loosened excessively, the housing may contact the turbine wheel or the compressor wheel and cause damage. Contact with the housing may cause rapid wear and shorten turbocharger life.
Attach a suitable lifting device to turbocharger (12). The weight of turbocharger (12) is approximately 79 kg (175 lb).
Remove bolts (13). Remove turbocharger (12).