811547A92 Mercruiser GASKET SET-OVERHAUL

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 gauge 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.
Put identification on all lines, hoses, wires and tubes for installation purposes. Cap and plug all lines, hoses and tubes to prevent foreign material from entering the system. Drain all fluids in a suitable container for storage or disposal.1. Remove the front bottom guard. Drain the coolant from the radiator in a suitable container. 2. Remove bolts (1) and remove two sections of fan guard (2). 3. Loosen clamp (3) and disconnect upper radiator hose (4) from the radiator. 4. Loosen clamp (7) and disconnect lower radiator hose (6) from the radiator.5. Remove power train oil cooler hose assemblies (5) and (9).6. Disconnect wire harness connector (8). 7. Attach suitable lifting straps to the radiator guard assembly as shown.8. Remove radiator guard assembly mounting bolts (10) from underneath the machine.9. Remove the radiator and the radiator guard assembly from the machine. The weight of the radiator is 281 kg (620 lb). Install in the reverse order.10. Install the front bottom guard.End By:a. install hood Refer to the Operation & Maintenance Manual for all fluid capacities and the proper filling procedures.Disassemble & Assemble Radiator
Start By:a. remove radiator and guard assembly 1. Install Tool (A) as shown and attach hoist.2. Remove bolts (1) from each side of the radiator guard.3. Remove bolts (2) from inside the radiator guard. 4. Remove bolts (3) from each side of the radiator guard and light bracket.5. Remove radiator (4) from the radiator guard. The weight of the radiator is 135 kg (300 lb). 6. Remove bolts (5) from the top and bottom of radiator (4) and remove shrouds (6).7. Remove hose assembly (7). 8. Remove bolts (8) from upper tank assembly (9).9. If necessary, attach hoist and remove upper tank assembly (9) form cores (11).10. Remove tank seals (10) from the upper tank assembly. 11. Remove bolts (12) from the core that is to be removed.12. Remove core (13) from the lower tank assembly. 13. Remove tank seal (14) from the lower tank assembly. The following steps are for the assembly of the radiator. 14. Lubricate sealing areas of tank seal (14) with 5P-3975 Rubber Lubricant or Liquid Soap and install tank seals (14). 15. Install cores (13) in the lower tank assembly and install bolts (12). 16. Lubricate sealing areas of tank seals (10) with 5P-3975 Rubber Lubricant or Liquid Soap.17. Install upper tank assembly (9) on cores (11).18. Install bolts (8). 19. Install shrouds (6) with bolts (5).20. Install hose assembly (7). 21. Install Tool (A) and install radiator (4) in the radiator guard. The weight of the radiator is 135 kg (300 lb).22. Install bolts (3). Do not tighten at this time. 23. Install bolts (1) and (2). Tighten bolts (1) and (2) at this time.24. Remove Tool (A).25. If necessary, pressure test radiator. The radiator must withstand 100 kpa (14.5 psi) water pressure.End By:a. install radiator and guard assembly