864547A02 Mercruiser GASKET, Full Flow

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     138-7574     Link Bracket     2    
ZZ     6V-9507     Face Seal Plug (9/16 - 18 THD)     3    
6V-9828 Cap Assembly (9/16 - 18 THD)     3    
6V-9508 Face Seal Plug (11/16 - 16 THD)     6    
6V-9829 Cap Assembly (11/16 - 16 THD)     6    
6V-9509 Face Seal Plug (13/16 - 16 THD)     12    
6V-9830 Cap Assembly (13/16 - 16 THD)     12    
6V-9511 Face Seal Plug (1 3/16 - 12 THD)     1    
6V-9832 Cap Assembly (1 3/16 - 12 THD)     1    Start By:
Remove the air cleaner. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".
Remove the radiator. Refer to Disassembly and Assembly, "Radiator - Remove and Install".Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.Note: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Personal injury can result from hydraulic oil pressure and hot oil.Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Disconnect batteries before performance of any service work.
Slowly loosen the filler cap on top of the hydraulic tank in order to release the pressure in the hydraulic system.
Drain the hydraulic oil from the hydraulic tank into a suitable container. Refer to the Operation and Maintenance Manual, "Hydraulic System Oil - Change" for the proper procedure. The capacity of the hydraulic tank is approximately 26 L (6.9 US gal).
Illustration 1 g01098640
Disconnect fuel hoses (2) from water separator (1) .
Disconnect hose assemblies (3) and (4) .
Remove clamp (5) .
Position hose assemblies (3) and (4) and fuel hoses (2) out of the way.
Illustration 2 g01098642
Remove bolts (7) and exhaust pipe (6) .
Loosen the clamp and disconnect coolant hose (8) from engine (9) .
Illustration 3 g01098650
Disconnect harness assemblies (12) from alternator (10) .
Disconnect harness assembly (11) from the sensor.
Illustration 4 g01098651
Disconnect harness assemblies (13) from electric starting motor (14) .
Illustration 5 g01098652
Disconnect ground strap (15) .