807209 Mercruiser FUEL LINE

1. Disconnect the three wires to starter solenoid (1).2. Remove one nut and washer (2), and disconnect two ground wires (3). 3. Disconnect two electrical connectors (4). 4. Remove two electrical connectors (5) from the support clips, and disconnect them. 5. Disconnect two hydraulic oil lines (6) from cooling pump (7).6. Disconnect cold starting aid tube (8).7. Remove electrical connector (9) from the support clip, and disconnect it. 8. Disconnect and cap two fuel lines (11).9. Remove the bolt holding fuel line support clip (12).
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.
The refrigerant compressor can either be removed from the engine or set aside. To avoid purging and recharging the air conditioning system, remove the bolts from the support clips for lines (10) and the bolts and belt from the refrigerant compressor and set it aside. If removal of the refrigerant compressor is preferred, see the topic "Remove And Install The Refrigerant Compressor" in this module.10. Purge the air conditioning system. See the topic "Purging The System" in the Air Conditioning And Heating Service Manual, Form No. SENR3334 for the correct procedure.11. Disconnect two refrigerant lines (10). 12. Disconnect heater hose (13).13. Remove exhaust shield (14). 14. Disconnect two lines (15) from transmission oil cooler (16). 15. Disconnect the three wire retaining clips and wire (17) from alternator (18).16. Disconnect heater hose (19). 17. Remove four bolts and washers (20) connecting drive shaft (21) to transmission yoke (22). 18. Support the engine with a hoist and tooling (A).19. Remove four bolts and washers (23) along with the upper half of mounting assemblies (24).20. Remove engine (25). The weight of the engine is 1000 kg (2200 lb). The following steps are for the installation of the engine. 21. Position four lower half mounting assemblies (26) in the machine frame. 22. Align the slots in transmission yoke (27) to approximately match the locating tabs on the universal joint of drive shaft (21). 23. Position four bolts and washers (23), and four upper half mounting assemblies (24) in the machine engine supports.24. Position the engine in the machine frame. Align bolts and washers (23) into lower mounting assemblies (26) as the engine is lowered into position.25. Install the washers and nuts onto four bolts (23). Remove the hoist and tooling (A).26. Align the tabs on drive shaft (21) with the slots in transmission yoke (27), and install four bolts and washers (20). Tighten four bolts (20) to a torque of 135 20 N m (100 15 lb ft).27. Install the three wire support clips, and connect wire (17) to the alternator (18).28. Connect heater hose (19).29. Connect two lines (15) to transmission oil cooler (16).30. Connect heater hose (13), and install exhaust shield (14). If the refrigerant compressor was set aside while removing the engine, reposition the compressor and install the belt and bolts. If refrigerant lines (10) were removed from the compressor, connect lines (10). See the topic "Complete Charging Of The System" in the Air Conditioning And Heating Service Manual, Form No. SENR3334, for the correct procedure to charge the system.
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.
31. Connect two fuel lines (11) and their clip (12).32. Connect two hydraulic oil lines (7) to cooling pump (6).33. Connect cold starting aid tube (8).34. Connect and install electrical connector (9) into its support clip.35. Connect and install electrical connectors (4) and (5) into the support clips.36. Connect three wires to starter solenoid (1) in their original positions.37. Position two ground wires (3), and secure with nut and washer (2).End By:a. install radiator assemblyb. install muffler and air cleaner assembly