806871A96 Mercruiser GASKET SET-OVERHAUL

4. Loosen the clamps and remove tube assembly and hoses (1) from the inlet side of the turbocharger. 5. Disconnect hoses (2) and lines from the air compressor. 6. Remove the bolts and disconnect bracket (3) from the engine. 7. Put identification marks on fuel lines (4) for correct installation. Disconnect fuel lines (4) from the engine.8. Remove the bolt and disconnect clip (5) from the engine.9. Disconnect ether start tube (6). 10. Remove the bolt and disconnect clip (7) that holds the ether start aid tube (6). 11. Loosen the clamps and disconnect water lines (8) from the engine.
View From Under Machine12. Put identification marks on hoses (9) for installation purposes. Disconnect hoses (9) from the engine transfer gear case. 13. Disconnect wire harnesses (10). 14. Put identification marks on starter and solenoid wires (11) correct installation purposes. Disconnect wires (11) the starter and solenoid. 15. Remove the mounting bolts for air conditioning compressor (12). Lay the air conditioner compressor in front of the cab. The air conditioner lines do not have to be disconnected from the compressor. 16. Fasten Tool (A) and a hoist on the engine (see Illustration D61050). 17. Install Tool (B) to hold the engine transfer gear case to the machine as shown. Tighten the bolts that hold the Tool to the machine frame. Install the bolts that hold the Tool to the transfer gear case but do nottighten them at this time. 17. Remove bolts (13) that hold the engine front support to the machine. 18. Remove the bolts and cap (14) from the left rear engine support so bolts (15) can be removed.19. Remove bolts (15) that hold the lift support to the flywheel housing. 20. Remove the bolt and clamp (16) so support bolts (17) can be removed. Remove bolts (17) that hold the right support to the fly wheel housing. 21. Remove bolts (18) that hold the engine transfer gears to the flywheel housing. 22. Use Tool (A) and a hoist to lift the engine a small amount and tighten the bolts that hold Tool (B) to the engine transfer gear case.23. Install two 1/2 in - 13 NC Forcing Screws(19) to separate the engine from the engine transfer gear case. 24. Use Tool (A) and a hoist and carefully remove engine (20) from the machine. The weight of the engine is 2449 kg (5400 lb).Install Engine
1. Inspect the O-ring seal on the engine transfer gear case for wear or damage and make a replacement if necessary.2. Put 5P-0960 Multipurpose Type Greaseon the rear engine supports to make installation of the engine easier. 3. Fasten Tool (B) and a hoist on engine (1) as shown. Lower the engine in the machine to the approximate height away from the machine's frame as when it was separated from the engine transfer gear case. 4. Install two 1/2 in - 13 NC x 4 in Guide Bolts(2) in the flywheel housing to make alignment between the engine and engine transfer gears easier.5. Use Tool (B) to put the engine as level as possible with the engine transfer gears.6. Carefully install the engine on the engine transfer gear case. Make sure the spider for the transfer gears is in alignment with the flywheel. Install the bolts that hold the engine transfer gears to the flywheel housing. 7. Install bolts (3) that hold the right engine support to the flywheel housing.8. Install clamp (4) that holds the hoses in place on the frame. 9. Install bolts (6) that hold the left engine support to the flywheel housing.10. Install cap (5) on the support as shown. 11. Install bolts (7) that hold the front support to the machine. 12. Remove Tool (A) from the machine frame and the engine transfer gear case. 13. Install air conditioner compressor (8) in the mounting bracket on the enigne. 14. Connect wires (9) to the starter and the solenoid. 15. Connect wire harnesses (10).
View from under the machine.16. Inspect the O-ring seals in hoses (11) for wear or damage and make a replacement if necessary.17. Connect hoses (11) to the engine transfer gears. 18. Connect water lines (12) to the engine.19. Connect ether start tube (13). 20. Connect fuel lines (14) to the engine.21. Connect clip (15) that holds the fuel lines in place. 22. Connect bracket (16) to the engine. 24. Connect air lines (17) to the air compressor.25. Install the front, the middle and the rear crankcase guards on the machines.26. Fill the engine transfer gear case with oil to the correct level. See the Operation And Maintenance Manual.End By:a. install radiator guard and radiatorb. install muffler Refer to the Topic "Lubricant Viscosities and Refill Capacities" in the Operation and Maintenance Manual for the proper filling procedure and the proper levels for the hydraulic system and the cooling system.