19039 Mercruiser NUT (Special)

Removing The Engine
HOT ENGINE COMPONENTS CAN CAUSE SERIOUS BURNS. SHUT THE ENGINE DOWN AND ALLOW IT TO COOL BEFORE WORKING IN THE ENGINE COMPARTMENT.
1. Close the fuel shutoff valve located under the fuel tank. 2. Remove the drain plug from the bottom of the radiator and allow the coolant to drain. After the coolant has drained, install the plug.3. Remove the fan drive belt band (see page 2.0-19, steps 1 through 3). 4. Unbolt and remove the turbo cover assembly.5. Attach a lifting device to the engine exhaust pipe and elbow. Unbolt the engine exhaust pipe from the air box exhaust pipe and the elbow from the engine, then remove the exhaust pipe and elbow from the machine. Cover all openings.6. Remove the radiator tubes.7. Attach a lifting device to the air cleaner mount. Disconnect the 90 degree elbows from the engine and unbolt the throttle cable clamp from the mount. Unbolt the air cleaner mount and lift the air cleaners, mount and intake ducting away. Cover all openings.8. Remove the drive line cover. Loosen the jam nut and turn the adjusting nut to relieve the pump drive gearbox drive belt tension. 9. Support the cutter clutch drive shaft, unbolt the drive shaft from the sheaves, then move the drive shaft away. Remove the drive belt from the power take-off sheave.
COMPRESSED AIR ESCAPING FROM THE SYSTEM CAN CAUSE SERIOUS INJURIES. STAY CLEAR OF ANY ESCAPING COMPRESSED AIR.
10. Open the drain valve on the air tank to relieve the air pressure. Mark for identification the hoses running from the tank to the compressor, then disconnect the hoses from the compressor. 11. Disconnect the throttle cable from the engine, unbolt the cable bracket and cable guide, then move the throttle cable, bracket and guide away from the engine and lay them where they will not be in the way during engine removal.12. Disconnect the following from the engine: Fuel hoses - cap or plug all openings.Tachometer cable.Starter solenoid electrical wires.Engine exhaust thermocouple wire.Alternator wires.13. Check the engine over and disconnect any remaining wires or hoses that might interfere with engine removal. Cap or plug all openings.14. Attach a lifting beam and device to the engine, remove the engine mounting bolts, then lift the engine away. The total weight of the engine is approximately 4500 pounds (2046 kg).Building The Engine Up
THERMOCOUPLE WATER TEMPERATURE SENDER OIL PRESSURE SENDER The simplest way to build up a new engine is to position the new engine beside the old one and properly support both so they can safely be worked on. Then remove one component at a time from the old engine and install it on the new engine until all required components have been transferred to the new engine. Components that may have to be transferred include:1. Alternator and drive belt.2. Fan drive sheave.3. Compressor, drive belt, compressor coolant hoses and compressor lubricant hose.4. Engine power take-off (see page 2.0-11 for procedures to remove the power take-off).5. Oil pressure switch, oil pressure sender, hoses and bracket.6. Water temperature sender.7. Tachometer drive.8. Engine exhaust thermocouple.9. Exhaust elbow support.Installing The Engine
1. Check that the mounting area on the machine is clear of all hoses, wires, control cables. etc.2. Attach a lifting beam and lifting device to the lifting lugs on the engine and move the engine into position. The approximate total weight of the engine is 4500 pounds (2046 kg). 3. Connect the following to the engine: Fuel hoses.Tachometer cable.Starter solenoid wires.Engine exhaust thermocouple wire.Alternator wires. 4. If the alternator drive belt has not been installed, install it and adjust the belt tension (see page 2.0-23), then install the spray system pump drive belt and adjust the belt tension (see page 2.0-22).5. If necessary, install the compressor drive belt and adjust the tension (see page 2.0-21). 6. Install the radiator tubes. 7. Connect to the compressor the air hoses from the air tank. Close the drain valve on the tank. 8. Slide the pump drive gearbox belt over the drive sheave, move the cutter drive shaft into position between the sheaves, then bolt the drive shaft to the sheaves. Adjust the pump drive gearbox belt tension (see page 2.0-25). Install the drive line cover. 9. Attach a lifting device to the engine exhaust pipe and elbow. Move the exhaust pipe and elbow into position, bolt the engine exhaust pipe to the air box exhaust pipe and the elbow to the engine.10. Attach a lifting device to the air cleaners and air cleaner mount. Move the air cleaners and mount into position and install the mounting bolts. Connect the 90 degree elbows to the engine.11. Install the turbo cover assembly. 12. Connect the throttle cable bracket, cable guide and cable to the engine. Connect the throttle cable clamp to the air cleaner mount. 13. Install the fan drive belt band and adjust the belt tension (see page 2.0-20, steps 4 through 6). 14. Fill the engine cooling system with a mixture of 50% water and 50% ethylene glycol antifreeze.15. Check the oil level in the engine and add oil as necessary. Be sure the correct oil is used. See General 2.0-1 for specifications. 16. Open the fuel shutoff valve. 17. Unlock the fuel priming pump.18. Operate the priming pump until increased resistance is felt, then lock the fuel priming pump.19. Start the engine and run it at the lowest RPM possible. Observe the auxiliary and engine oil pressure gauges during initial startup. If the auxiliary system pressure does not reach 2250 psi (15 513 kPa) within 5 seconds, or engine oil pressure does not indicate within 15 seconds, SHUT THE ENGINE DOWN and correct the problem.
HOT OR MOVING COMPONENTS IN THE ENGINE COMPARTMENT CAN CAUSE INJURIES. STAY ALERT WHEN WORKING ON OR NEAR A RUNNING ENGINE.
20. If the engine misfires or smokes, loosen a fuel injection line nut and allow the fuel to flow until free of air bubbles. Tighten the line nut, open the next line nut and continue priming each successive line.21. Increase the engine