808213 Mercruiser OIL FILLER CAP

At operation temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level 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 prevent personal injury.
Release the pressure in the cooling system by slowly loosening the filler cap on the radiator. Drain the coolant from the radiator and oil from the hydraulic oil cooler.
At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the hydraulic system before and hydraulic lines or components are disconnected or removed.
Release the pressure in the hydraulic system as follows:a. shut off the engine.b. Move the control levers through their full travel strokes. This will relieve any pressure that may be present in the pilot system.c. Slowly loosen the air breather cap on the hydraulic oil tank to release the pressure.d. Tighten the air breather cap on the hydraulic oil tank.e. The pressure in the hydraulic system has now been released. Lines and components can now be removed.
Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publication SENR3334-01, SENR5664 and NEDG5065-01 for the proper procedure, equipment and tools to reclaim refrigerant from any Caterpillar machine.
Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping refrigerant R-12 (CC12F2 Dichloro Difluoro Methane) and refrigerant R-134A can cause freezing of human flesh. Do not smoke while working on air conditioning. Inhaling Refrigerant R-12 or R-134A through any smoking material, although not toxic or flammable, can cause violent illness. Also heat must never be applied to a charged system. See Air Conditioning And Heating Service Manual Form No. SENR3334-01 and SENR5664, for more information on removal and installation of lines and refrigerant from the system.
Release the refrigerant R-12 from the system. See Air Conditioning And Heating, Purging The System, Form No. SENR3334-01. 1. Loosen clamps (1) and (2) and remove two hoses (3). Loosen large clamp (4) and slide large hose (5) down from water pump. 2. Remove four bolts (6) and remove elbow (7). 3. Disconnect one line (8). Remove five bolts (9) and remove water pump cover (10). 4. Remove four bolts (12) on elbow (13). Disconnect line (14) and remove three nuts (11) on pump. 5. Pull elbow (15) out of way to get last nut loose on pump (16). 6. Remove O-ring seal (17). Install in the reverse order.7. Inspect and replace if necessary all O-ring seals and gaskets. See Air Conditioning And Heating Service Manual, Form No. SENR3334 for the correct procedure to charge the system. Fill radiator with coolant. See Operation & Maintenance Manual for the proper procedure and levels. Fill hydraulic tank with hydraulic oil. See Operation & Maintenance Manual for the proper procedure and levels.Disassemble Water Pump
Start By:a. remove water pump 1. Remove O-ring seal (1) from adapter (2).2. Remove adapter (2) with a screwdriver. Remove the seal from the edge of adapter (2).3. Remove bolt (3) and washer. 4. Remove impeller (4) from the water pump housing with tooling (A). 5. Remove seal assembly (5). Remove ring and seal (6). 6. Remove the bolt and washer that hold gear (7) on the water pump shaft.7. Remove gear (7) with tooling (B).8. Remove bolts and retainer (9).9. Remove O-ring seal (8). 10. Remove shaft (10) and bearings as a unit.11. Remove bearing (11), spacer (12) and bearing (13) from shaft (10).12. Remove lip type seal from the gear side of the water pump. Remove ring and seal from the impeller side of the water pump.Assemble Water Pump
1. Put clean engine oil or glycerine on the lip of seal (1). Install seal (1) as shown with tooling (A). 2. Install bearing (4), spacer (3) and bearing (5) on shaft (2). Install shaft (2) in the pump housing. 3. Install retainer (7) and O-ring seal (8).4. Install gear (6). Install washer and bolt that hold gear (6) to shaft (2).
Clean water only is permitted for use as a lubricant for assistance at installation. Do not damage or put hands on the wear surface of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal assembly.
5. Put ceramic ring (10) in position in the rubber seal (9). Use hand pressure and tool (11) (which is with the replacement ring) to install the ceramic ring in the housing. 6. Remove the spring from seal assembly (12). Use hand pressure and tool (11) (which is with the replacement ring) to install the seal assembly. Push seal assembly on the shaft until the seal faces make light contact. 7. Install spring (13) on the seal assembly and impeller (14) on the shaft. Install the bolt and washer on the shaft. Tighten the bolt to a torque of 39 3 N m (29 2 lb ft). 8. Install O-ring seals (15) on adapter (16). Put clean engine oil on O-ring seals.9. Install adapter (16) in the pump housing. Make sure the notch in the adapter is in alignment with dowel (17).End By:a. install water pump