21923 Mercruiser NUT, SWITCH TERMINAL STUD (8-32)

1. Remove the bolts that hold the gauge panel (4) to the front plate (1). Remove the panel from the plate.2. Remove the bolts and brace (3) from the cylinder head. Remove the bolts that hold front plate (1) to the engine front support. Remove the plate with a hoist. Weight is 60 lb. (27 kg).3. Remove the nuts that hold dust ejector tube (5) to the muffler. Loosen the clamp that holds the muffler (2) to the elbow for the turbocharger. Remove the muffler with a hoist. Weight is 60 lb. (27 kg). 4. Put identification on cables (7) and the three wires on the starting motor and disconnect them. Disconnect hose (6) for fuel pressure to the gauge panel.5. Remove the cotter pin and the pin that hold rod (8) to the lever on the governor control. Remove the bolts that hold housing (9) to the timing gear plate and cover. Put the housing and the linkage on the tandem housing. 6. Drain the coolant from the cooling system. Remove the plug from the bottom of elbow (12) and drain the coolant from the elbow and the tube from the radiator. Loosen the hose clamps that hold the hoses to elbow (12). Remove elbow (12).7. Loosen the hose clamps from hose (11). Remove tube (10) for coolant to the water pump. 8. Remove the bolt that holds clip (13) and the hoses. Disconnect oil line (20) from the connector.9. Put identification on wires (17) and disconnect them from the oil pressure switch. Disconnect wire (15) from the wire harness for the glow plugs.10. Remove line (14) from the water temperature sensor. Disconnect wire (16) from the coolant flow switch.11. Disconnect air outlet line (18) from the air compressor. Disconnect air line (19) from the air compressor governor.12. Disconnect oil lines (21) from the transmission oil cooler. 13. Fasten a hoist and chains to the lifting eyes on the engine. Remove bolts (23) that hold the engine front support to the frame. Remove bolts (22) that hold the flywheel housing to the transmission flange. Move the engine forward and remove it from the machine. Weight is 1800 lb. (815 kg). Keep the shims that are between the engine front support and the frame in their correct relationship with the engine front support for use during installation.Install Engine (130G & 120G)
1. Fasten a hoist and chains to the lifting eyes on the engine. Put the engine in position on the machine.2. Move the engine back toward the transmission until the flywheel and the coupling for the transmission are engaged. 3. Install shims (3) in their correct locations under the engine front support. Remove the hoist.4. To make sure the engine and the transmission are in correct alignment, the following procedure must be used: a) Install two bolts in the top of the transmission flange and tighten them.b) Install the bolts that hold the engine front support to the frame but do not tighten them. These bolts are for alignment only at this time. c) Measure the gap at location (X) with a feeler gauge. Add or remove shims from under the engine front support to get a .003 to .005 in. (0.076 to 0.127 mm) gap at location (X). When the bolts that hold the engine front support are tightened, this gap will be even.5. Tighten the bolts that hold the engine front support to the frame. Install the remainder of bolts (4) that hold the flywheel housing to the transmission flange and tighten them. 6. Connect battery cables (7) and the three wires to the starting motor.7. Put housing (6) in position on the timing gear plate. Install the bolts that hold it to the plate and the timing gear cover.8. Put rod (5) in position on the lever for governor control. Install the pin and the cotter pin that hold it. 9. Connect air line (8) to the air compressor. Connect air line (9) to the air compressor governor.10. Connect wires (14) to the oil pressure switch. Connect wire (10) to the wire harness for the glow plugs. Connect wire (11) to the coolant flow switch.11. Connect oil lines (12) to their correct locations on the transmission oil cooler. Connect oil line (13) to the fitting. 12. Install line (15) for water temperature to the sensor in the cylinder head.13. Put tube (17) in position on the machine. Install the hoses and the hose clamps on each end of the tube.14. Put elbow (16) in position in the hoses for the tube and the water pump. Install the bolt that holds the elbow to the engine front support.15. Tighten all the hose clamps for the elbow and the tube. 16. Fasten a hoist to muffler (19) and put it in position on the elbow for the turbocharger. Tighten clamp (21). Install dust ejector tube (22) and the nuts that hold it to the muffler.17. Fasten a hoist to plate (18) and put it in position on the machine. Install the bolts that hold the plate to the engine front support. Install the bolt that holds brace (20) to the cylinder head. Put the gauge panel in position on plate (18) and install the bolts that hold it. Fill the cooling system with coolant.end by:a) install fuel tank (120G)b) install pump group drive shaft