805299A 1 Mercruiser FLAME ARRESTOR

1. Remove tube assemblies (1) and (2) from the torque converter and the oil cooler. 2. Disconnect wire harness (3) at the firewall. 3. Disconnect heater hoses (4) and (5) and remove the clips that hold them to the engine. 4. Disconnect air lines (6) and (7). 5. Remove four bolts (9), tube (8) and the water temperature regulator. 6. Loosen hose clamps (10) and (12).7. Remove bolts (13) and tube assembly (11). 8. Loosen hose clamp (15) and remove tube (14). 9. Disconnect control cable (16) from the governor.10. Remove the bolts that hold bracket (17) to the engine. Move the control cable and bracket away from the engine. 11. Put identification on wires (18) and (19). Disconnect wires (18) and (19) from the solenoid and starter. 12. Disconnect wire harnesses (20) at the flywheel housing. 13. Disconnect air conditioning lines (21) from the air conditioning compressor. 14. Disconnect fuel lines (22) and (23). 15. Remove clips (24) and (25) from the cylinder block. Fasten the fuel lines to the side of the frame so they are clear of the engine. 16. Remove the bolts that hold disconnect switch (27) in place.17. Remove bolts (26) from the engine mounts. 18. Put floor jack (28) in position under the transmission housing so it will not fall when the engine is removed. 19. Fasten a hoist to engine (29) as shown. Install tooling (A) on the front cover.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 1058 kg (2350 lb.). If necessary, use forcing screws to make a separation of the transmission case and flywheel housing. 22. Put blocks (30) between transmission case (31) and the front support of the rear axle.Install Engine
1. Fasten a hoist and tooling (A) to the engine. Put engine (1) 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. Remove the blocks from under the transmission housing. 4. Install front mounting bolts (2).5. Put disconnect switch (3) in position and install the bolts. 6. Put the fuel lines in position and install clips (4) and (5) that hold the fuel lines to the cylinder block. 7. Connect fuel lines (6) and (7). 8. Connect air conditioning lines (8) and (9) to the air conditioning compressor. 9. Connect wire harnesses (10) at the flywheel housing. 10. Connect wires (11) to the solenoid and wires (12) to the starter. 11. Put bracket (14) in position and install the bolts.12. Connect control linkage (13) to the governor. 13. Put tube (15) in position and install the hose clamp. 14. Put tubes (16) and (18) in position and install hose clamps (17). 15. Put the water temperature regulator, the gasket and tube (19) in position and install the bolts. 16. Connect air lines (20) and (21) to the tubes. 17. Connect heater hoses (22) and (23) as shown. Install clip (24). 18. Connect wire harness (25) at the firewall.19. Make sure the O-ring seals are in place in the tube assemblies. 20. Install tube assemblies (26) and (27).21. Fill the transmission with oil to the correct level. See LUBRICATION AND MAINTENANCE GUIDE.22. Fill the hydraulic tank with hydraulic oil to the correct level. See LUBRICATION AND MAINTENANCE GUIDE.23. See AIR CONDITIONING AND HEATING SERVICE MANUAL, Form No. SENR7454, for charging the air conditioning system.end by:a) install rear drive shaftb) install air cleanerc) install mufflerd) install radiator and guard