850488 Mercruiser HOUSING

Start By:a. remove hoodb. remove alternatorc. remove fan drive
At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Drain the coolant only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to avoid personal injury.
1. Release the pressure in the cooling system by slowly loosening the fill cap on the radiator. Drain the coolant from the cooling system by placing a drain hose through the hole in the back of the bumper and opening the drain valve. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to the "Operation & Maintenance Manual" for cooling system capacities. 2. Remove two hose clamps (2) and top radiator hose (1). Some of the engine compartment components have been removed for better photo illustration. 3. Remove two hose clamps (3) and slide bottom hose (4) off the elbow. 4. Remove bolts (5) and air dryer group (6) from the radiator shroud. 5. Remove bolts (7) and transmission oil cooler (8) from the radiator shroud. 6. Remove bolts (10) and two piece shield (9) from the radiator shroud. 7. Remove bolts (11) that hold air conditioner condenser (12) to the radiator shroud. Air conditioner condenser (12) can be laid back on the transmission housing. 8. Remove bolts (13) and use two people to remove radiator grill (14) from the radiator shroud.9. Disconnect the taillight wiring harness on radiator grill (14). The weight of radiator grill (14) is 24 Kg (53 lb). 10. Remove bolts (17) and plate (18) from the front of the shroud.11. Remove the taillight wiring harness and grommet (16) from plate (18).12. Remove six bolts (15), two bolts on each side are located under the plate assembly on the inside of the radiator shroud. 13. Secure Tooling (A) to the radiator shroud. Fasten a hoist and lifting nylon straps to Tooling (A) and remove the radiator shroud from the machine. The weight of the radiator shroud and the radiator group is 114 kg (250 lb). 14. Remove six bolts (19) from the radiator group. Two of the bolts are at the top of the radiator and four are at the bottom, as shown. The radiator group will slide out of the radiator shroud. The weight of the radiator group is 57 Kg (125 lb). The following steps are for the installation of the radiator. Check the condition of the radiator prior to installation. Remove any dirt or debris that may restrict the flow of air through the core. If any of the cooling fins are bent, they should be straightened.15. Clean any dirt off of the frame and the bottom of the radiator group. Check the condition of the O-ring seals used in the hose assemblies that were disconnected. If any of the O-ring seals are damaged, use new parts for replacement.16. Slide the radiator group into the radiator shroud. The weight of the radiator group is 57 Kg (125 lb).17. Install six bolts (19) to the radiator group. Two of the bolts are at the top of the radiator and four are at the bottom, as shown.18. Fasten a hoist and nylon lifting straps to Tool (A) and position the radiator shroud on the frame. The weight of the radiator shroud is 114 Kg (250 lb).19. Install six bolts (15), two bolts on each side are located under the plate assembly on the inside of the radiator shroud.20. Install the taillight wiring harness and grommet (16) to plate (18).21. Install plate (18) and bolts (17) to the front of the shroud.22. Connect the taillight wiring harness on the radiator grill. Use two people and position the radiator grill (14) on the radiator shroud. The weight of radiator grill (14) is 24 Kg (53 lb).23. Install radiator grill (14) and bolts (13) to the radiator shroud.24. Install air conditioner condenser (12) and bolts (11) to the radiator shroud.25. Install two piece shield (9) and bolts (10) to the radiator shroud.26. Install transmission oil cooler (8) and bolts (7) to the radiator shroud.27. Install air dryer group (6) and bolts (5) to the radiator shroud.28. Position bottom hose (4) to the elbow and install two hose clamps (3).29. Install top radiator hose (1) and two hose clamps (2).30. Fill the radiator to the proper level with engine coolant. Refer to the "Operation & Maintenance Manual" for the proper procedures in order to fill the radiator.End By:a. install fan driveb. install alternatorc. install and hood