809933127 Mercruiser LOCKWASHER

Start By:a. remove hoodb. remove hydraulic oil coolerc. remove radiator and condenserd. remove cab Drain the oil from the hydraulic tank and the transmission. 1. Open engine door latch (1).2. Open door (3).3. Remove bolt (2) on door hinge.4. Remove door (3). 5. Shut off (4) for fuel tank. 6. Install cab mounting bolts (5) in place as shown.7. Install a sling from hoist as shown. 8. Remove bolts (6) from each side.9. Remove Rops. Weight of the Rops 125 kg (275 lb). 10. Remove support clamp and remove air condition drier (7).11. Disconnect governor control rod end (8). 12. Disconnect two fuel lines (9) at engine.13. Disconnect ether start line (10).14. Disconnect electric connector at starting aid solenoid (11). 15. Remove two bolts and remove circuit breaker box (12). 16. Attach tooling (A) and lifting straps as shown.17. Remove one bolt (13) from each side of firewall (14)18. Remove two bolts (15) each side.19. Remove support assembly (16). 20. Remove support clamps (17) from fuel lines (18).21. Pull fuel lines through firewall and remove rubber grommets. 22. Disconnect governor control rod (19) from governor control lever (20).23. Remove three bolts (21) from each side of firewall (14).24. Remove firewall (14). 25. Disconnect ground cable and wire (22).26. Disconnect two sure seal connectors (23) and clamp bolt (24).27. Disconnect sure seal connector (25).28. Disconnect wires from starter and solenoid (26). 29. Disconnect hose (27). 30. Disconnect two air condition lines (28) at the air condition pump (29). 31. Follow wire harness (30) back to frame and remove plastic frame clips.32. Remove intake to pump hose (31).33. Disconnect transmission pump hose (32).34. Remove hydraulic hose (33). 35. Disconnect hose (34), (35), (36) from priority valve. 36. Drain transmission.37. Remove fill tube (37).38. Remove drive shaft (38). 39. Remove universal shaft (39). 40. Disconnect two heater hoses (41). 41. Fasten tool (A) and a hoist to the engine, transmission and transfer gears as shown.42. Remove bolts (40) from the front mounting supports. 43. Loosen bolt (40) on rear mounting support bracket enough so that the engine can be lifted slightly to properly adjust tooling (A).44. After proper balance has been achieved with tooling (A), remove four bolts (42) that hold mounting brackets (43) to the transfer case.45. After removing four bolts (42) from both mounting brackets (43), remove the one (40) that holds the mounting bracket directly above the transfer case drain plug and remove bracket (43).
Inspect the areas in and around the engine and power train unit to make sure all disconnections and removals have been made before the engine and power train unit are to be lifted from the mounting frame.
46. Slowly lift engine, transmission and transfer gears out of the machine. The weight of engine and power train unit (44) is 1558 kg (2125 lb). Once the engine and power train unit has cleared hoses, wiring and machine frames, move the unit away and support it in a proper, safe and suitable manner. Install in the reverse order.End By:a. install cabb. install radiator and condenserc. install hydraulic oil coolerd. install hood47. Fill the cooling system with coolant to the correct level. See the Operation & Maintenance Manual.48. Fill the hydraulic system with hydraulic oil to the correct level. See the Operation & Maintenance Manual.Separation & Connection Of Engine From Transmission & Transfer Gears
Start By:a. remove engine, transmission and transfer gears 1. Put the engine, transmission and transfer gears on a suitable stand with supports under the transfer gears.
Typical Example2. Remove wire clamp (1).3. Disconnect wiring harnesses (2) and (3). 4. Fasten tooling (A) and a hoist to the transmission and remove the supports from the transfer gears.5. Remove twelve bolts (4) that holds the transmission to the engine. 6. Remove transmission and transfer gears (5) from the engine. The following steps are for the connection of the transmission and transfer gears to the engine.7. Fasten tooling (A) and a hoist to transmission and transfer gears (5) and put it in position on the engine.8. Install twelve bolts (4) that hold the transmission and transfer gears to the engine.9. Put supports under the transfer gears and remove the hoist.10. Connect wiring harnesses (2) and (3).11. Install clamp (1).End By:a. install engine, transmission and transfer gears