805470 Mercruiser DRIVER GUIDE

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
ZZ     9U-7075     Cap     1    
9U-7076 Cap     1    
9U-7074 Cap     2    Start By:
Remove the counterweight. Refer to Disassembly and Assembly, "Counterweight - Remove and Install".
Remove the V-belt from the refrigerant compressor. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.
Personal injury can result from contact with refrigerant.Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area.Personal injury or death can result from inhaling refrigerant through a lit cigarette.Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death.Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.
Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publications Service Manuals, SENR3334, SENR5664, and NEDG5065 for the proper procedure, the proper equipment, and the proper tools needed in order to reclaim refrigerant from any Caterpillar equipment.
Personal injury can result from contact with refrigerant.Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area.Personal injury or death can result from inhaling refrigerant through a lit cigarette.Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death.Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.
Recover the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the correct tools.
Illustration 1 g01000925
Disconnect harness assembly (1) .
Illustration 2 g01000926
Remove bolt (3), the clip, and bolt (4) .
Disconnect tube assemblies (2) .
Illustration 3 g01000927
Remove bolts (5) and refrigerant compressor (6) .Installation Procedure
Illustration 4 g01000927
Position refrigerant compressor (6) and install bolts (5) .
Illustration 5 g01000926
Install new O-ring seals on tube assemblies (2) .
Connect tube assemblies (2). Install bolt (3), the clip, and bolt (4). Tighten the bolts to a torque of 28 6 N m (243 58 lb in).
Illustration 6 g01000925
Connect harness assembly (1) .
Evacuate the air conditioner system. Charge the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the correct tools.
Charge the air conditioning system. The correct charge is 0.9 kg (2.0 lb). Refer to Testing and Adjusting, "Refrigerant System - Charge" for the correct procedure.End By:
Install the V-belt on the refrigerant compressor. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".
Install the hood on the refrigerant compressor. Refer to Disassembly and Assembly, "Ho