806653A 1 Mercruiser FITTING ASSEMBLY (INLET)

Start By:a. install body retaining pins Fluid Spillage ContainmentCare must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Product Guide, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gage to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
1. Drain the coolant from the engine cooling system in a suitable container to a level below the radiator top tank assembly. 2. Open front hood assembly (3). Remove four bolts (4) and the washers that hold front hood assembly (3) to the frame assembly. Remove cotter (1) and the washer that holds prop assembly (2) to front hood assembly (3). Close front hood assembly. 3. Remove ten bolts (6) and the washers that hold rail assembly (5) to front hood assembly (3). Put lifting slings in position around rail assembly (5). Attach the lifting slings to a suitable lifting device. Remove rail assembly (5) from front hood assembly (3). The weight of rail assembly (5) is 25 kg (55 lb).4. Remove five bolts (7) and the washers that hold front hood assembly (3) to cowling assembly (8). 5. Install Tooling (A) on front hood assembly (3). Attach Tooling (A) to a suitable lifting device. Remove front hood assembly (3). The weight of front hood assembly (3) is 62 kg (136 lb). 6. Remove the four bolts from each elbow (10) and (11). Disconnect two elbows (10) and (11) from radiator top tank assembly (9). Remove the gasket from each elbow (10) and (11).7. Remove four straps (12) that hold harness assembly (13). Set harness assembly aside. 8. Remove eight bolts (15) and the washers. Remove two fan guard assemblies (14) from strips (16).
Prior to removal of the fan assembly, put a piece of cardboard between the fan spider assembly and the folded cores. Failure to do so could result in part damage.
9. Put a lifting sling around the fan assembly. Attach the lifting sling to a suitable lifting device. Remove six bolts (17). Remove fan adapter (18) and the fan spider assembly as a unit from fan pulley hub (19). The weight of fan adapter (18) and the fan spider assembly as a unit is 59 kg (130 lb). The following steps are for the installation of the fan and fan guard.
Prior to installation of the fan assembly, put a piece of cardboard between the fan spider assembly and the folded cores. Failure to do so could result in part damage.
10. Put a lifting sling in position around the fan assembly. Attach the lifting strap to a suitable lifting device. Put fan adapter (18) and the fan spider assembly as a unit in position on fan pulley hub (19). Install six bolts (17). 11. Put two fan guard assemblies (14) in position on strips (16). Install eight bolts (15). 12. Put harness assembly (13) in position on the clips. Install four new straps (12) to hold harness assembly (13) to the radiator group.13. Clean all gasket material off the mating surfaces of two elbows (10) and (11). Put two elbows (10) and (11) and the gaskets in position on radiator top tank assembly (9). Install the four bolts that hold each elbow (10) and (11) to radiator top tank assembly (15). 14. Install Tooling (A) on front hood assembly (3). Attach Tooling (A) to a suitable lifting device. Put front hood assembly (3) in position on the frame assembly and the cowling assembly. 15. Install five bolts (7) and the washers that hold front hood assembly (3) to cowling assembly (8).16. Put a lifting sling in position around rail assembly (5). Attach lifting sling to a suitable lifting device. Put rail assembly (5) in position on front hood assembly (3). Install ten bolts (6) and the washers that secure rail assembly (5) to front hood assembly (3). 17. Open front hood assembly (3). Put prop assembly (2) in position on front hood assembly (3). Install the washer and cotter (1).18. Install four bolts (4) and the washers that hold front hood assembly (3) to the frame assembly.19. Refill engine cooling system with coolant to the correct level. Refer to the Operation & Maintenance Manual for all fluid capacities and the proper filling procedures.End By:a. remove body retaining pins