860616002 Mercruiser HARNESS ASSEMBLY, (23 Feet), Instrument Extension

Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 1 Start By:
Install the wheel chocks. Refer to Disassembly and Assembly, "Wheel Chocks (Front and Rear) - Remove and Install".
Personal injury can result from hot coolant, steam and alkali.At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand.Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.
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, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Position a suitable container under the radiator drain valves in order to contain the coolant for storage or disposal. Drain approximately 265 L (70 US gal) of coolant from the left side of the radiator. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct procedure.
Install caps and plugs on all openings in order to prevent dirt or debris from entering the system. Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
Raise the front hood assembly and the rear hood assembly.
Illustration 1 g00567078
Disconnect hose assembly (1) from elbow (5). Loosen two hose clamps (3) that hold hose (4) to elbow (5) and tube assembly (2).
Illustration 2 g00567079
Put identification marks on four bolts (6) for installation purposes. Remove four bolts (6) that hold elbow (5) to auxiliary water pump (7). Remove elbow (5) from auxiliary water pump (7).
Illustration 3 g00567080
Remove O-ring seal (8) from auxiliary water pump (7).
Illustration 4 g00567081
Disconnect hose assembly (12) from elbow (11). Remove two bolts (10), the washers, and the retainers that hold tube (9) to elbow (11).
Illustration 5 g00567082
Put identification marks on four bolts (14) for installation purposes. Remove four bolts (14), the washers, and the nuts that hold elbow (11) to auxiliary water pump (7). Remove elbow (11) and gasket (13) from auxiliary water pump (7).
Illustration 6 g00567084
Remove O-ring seal (15) and the retaining ring from tube (9).
Illustration 7 g00567086
Disconnect hose assembly (16) from auxiliary water pump (7).
Illustration 8 g00567087
Disconnect hose assembly (18) from the front housing. Loosen bolt (20) that holds idler pulley assembly (19) to the bracket. Remove V-belt (17).
Illustration 9 g00567088
Remove eight bolts (21) and the washers that hold pulley assembly (22) to the auxiliary drive shaft (not shown). Remove pulley assembly (22) from the auxiliary drive shaft (not shown).