816329A 3 Mercruiser EXHAUST MANIFOLD (3.0L)

2. Remove nuts (2) and disconnect the disconnect switch (1) from the frame.
Release the pressure in the air reservoir before any lines are disconnected.
3. Disconnect air lines (3) from the engine. 4. Turn valves (4) and (5) to the "CLOSED" position. Disconnect heater hoses (6) and (7) from the engine. 5. Put identification on wires (8), (9) and (10). Disconnect wires (8), (9) and (10) from the starter and the solenoid.
Always wear goggles when the air conditioning system is opened. This system is charged with Freon-12 (CCL2F2-Dichlorodifluoromethane) which is not toxic or flammable. But there is a reason for caution. When Freon-12 makes contact with a flame, lethal phosgene gas is made. INHALING FREON THROUGH A LIGHTED CIGARETTE CAN CAUSE VIOLENT ILLNESS. This system is under pressure at all times, engine running or not. HEAT MUST NEVER BE PUT ON A CHARGED SYSTEM. See AIR CONDITIONING AND HEATING SERVICE MANUAL Form No. SENR3334 for more information on procedures and safety requirements on removal and installation of lines and refrigerant from the system.
6. Disconnect air conditioning lines (11) from the air conditioning compressor.7. Disconnect the throttle linkage/governor control from the fuel injection pump housing. See Remove Fuel Injection Pump Housing And Governor (Earlier) or Remove Fuel Injection Pump Housing And Governor (Later). 8. Put identification on wire harnesses (12) and disconnect them at the rear of the machine. 9. Disconnect fuel lines (13) from the fuel injection pump housing and the rear of the engine.10. Disconnect clips (14) that hold the fuel line to the oil pan. 11. Put identification on the wire assembly (15) and disconnect them from the sending unit at the torque converter housing.12. Disconnect the clip that holds wire assembly (15) on top of the relief valve. 13. Remove the bolts and lower tube assembly (16) that connects the oil cooler to the torque converter. 14. Remove the bolts and upper tube assembly (17) that connects the oil cooler to the torque converter. 15. Remove the bolts and nuts and remove muffler brackets (18) and (19) from the engine. 16. Loosen clamp (21) and disconnect the clip from the engine. Remove breather tube (20) from the engine. 17. Install block (22) and an approved floor jack (23) as a support for the transmission so it will not fall when the engine is removed. 18. Fasten tool (A) to engine (24) as shown. 19. Remove bolts (25) and (26) from the front engine mounts.20. Remove the bolts that hold the transmission case to the flywheel housing.21. Lift up on the engine a small amount and remove it. The weight of the engine is approximately 838 Kg (1850 lb.). If necessary, use forcing screws to make a separation of the transmission case and the flywheel housing.Install Engine
1. Fasten a hoist and tooling (A) to engine (24). Put the engine in position and make an alignment of the flywheel and the torque converter. For easier installation keep the engine level. Make sure the O-ring seal is in position on the transmission case.2. Install the bolts that hold the flywheel housing to the transmission.3. Install front mounting bolts (25) and (26). 4. Remove block (22) and approved floor jack (23) from the under the transmission housing. 5. Install the breather tube (20) and connect the clip and clamp (21) to the engine. 6. Install muffler brackets (18) and (19) to the engine. 7. Install upper tube assembly (17) to the oil cooler and torque converter. 8. Install lower tube assembly (16) to the oil cooler and torque converter. 9. Connect wire assembly (15) to the sending unit on the torque converter and install the bolt that holds the wire clip to the top of the relief valve. 10. Connect fuel lines (13) to the fuel injection pump housing and at the rear of the engine.11. Connect fuel line clips (14) to the oil pan. 12. Connect wire harnesses (12) at the rear of the engine.13. Connect the throttle linkage/governor control to the fuel injection pump housing. See the topic, Install Fuel Injection Pump Housing And Governor (Later) or Install Fuel Injection Pump Housing And Governor (Earlier). 14. Connect air conditioning lines (11) to the air conditioning compressor. See Air Conditioning And Heating Service Manual, Form No. SENR3334. 15. Connect wires (8), (9), and (10) to the solenoid and to the starter. 16. Connect heater hoses (6) and (7) to the engine.17. Turn valves (4) and (5) to the "OPEN" position. 18. Connect air lines (3) to the engine as shown. 19. Connect engine disconnect switch (1) to the frame and install nuts (2).20. Install the muffler.End By:a. install rear drive shaftb. install air cleaner groupc. install radiator and guard (later) or install radiator, oil cooler and guard (earlier).