809064 Mercruiser OVERHAUL KIT

Start By:a. remove engine enclosure group1. Drain the oil from the hydraulic oil tank into a suitable container for storage or disposal. The capacity of the hydraulic oil tank is 135 liters (35.1 U.S. gal). 2. Put a suitable floor jack in position under step group (2) on the engine side of the machine. Fasten the step group to the floor jack.3. Remove four bolts (1) that hold step group (2) in position. Two bolts are located at the front of the step group. Two bolts are located at the rear of the step group.4. Carefully lower the step group and remove it from the machine. The weight of the step group is 113 kg (250 lb).
View From Under Machine5. Remove eight hex head fasteners (4). Remove front cover (5) and rear cover (3) from under the engine.
At Operating 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 slowly to relieve pressure in the cooling system. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
6. Release the pressure in the cooling system by slowly loosening the fill cap on the radiator.7. Drain the coolant from the cooling system into a suitable container for storage or disposal. The capacity of the cooling system is 35 liters (9.1 U.S gal). 8. Loosen the two clamps, and remove upper radiator hose assembly (6). 9. Loosen the two clamps, and remove lower radiator hose assembly (7). 10. Remove tie wrap (10). Loosen clamp (8). Disconnect heater hose (9) from the engine. Loosen clamp (12). Disconnect heater hose (11) from the engine. 11. Disconnect inlet hose assembly (15) from the fuel priming pump. Put a plug in the end of the hose assembly to prevent loss of fuel. Disconnect outlet hose assembly (14) from the fuel priming pump. Put a plug in the hose assembly to prevent loss of fuel. Remove four clips (13) that hold inlet hose assembly (15) in position on the right side and rear of the engine. 12. Remove the electrical wires from the left and right side of water temperature regulator housing (16).13. Put identification marks on all wires (17) connected to the back side of the alternator. Disconnect the wires from the back side of the alternator. Remove clip (18).14. Cut all tie wraps. Disconnect electrical connector (19) at the water pump.15. Remove clip (21). Remove the bolt and washer that hold alternator/starter ground wire (20) to the cylinder block. 16. Put identification marks on all wires (22) and cables (23) that are connected to the electric starting motor and the starter solenoid. Disconnect all wires and cables from the electric starting motor and starter solenoid. 17. Put identification marks on all hose assemblies (25) and tube assemblies (24) that are connected to the main hydraulic pump, the swing pump and the swing charge pump for installation purposes. Disconnect the hose assemblies and tube assemblies from the pumps. Put plugs in all hose assemblies and tube assemblies to prevent oil loss and to keep dirt and debris out of the hydraulic system.
View From Under Engine18. Disconnect hose assemblies (26), (27) and (28) from the brake/pilot pump. The brake/pilot pump is located on the lower left front of the engine. 19. Disconnect upper hose assembly 930) for the brake/pilot pump at firewall connection (29). 20. Disconnect wiring harness (31) for the governor cylinder. 21. Remove clip (33). Disconnect wire assembly (32) from the governor cylinder. 22. Disconnect hose assemblies (34) and (35) from the governor cylinder. Put plugs in the ends of the hose assemblies. 23. Put identification marks on three wires (36) that are connected to the fuel shutoff solenoid. Disconnect the three wires from the fuel shutoff solenoid. 24. Remove tie wrap (37) from the wires that are routed to the fuel shutoff solenoid and the air conditioning compressor. 25. Disconnect wiring harness (38) for the air conditioning compressor. 26. Loosen bolts (39) and (40). Remove the nuts, washers and bolts (41) that hold plate (42) to air conditioning compressor (43). 27. Remove the air conditioning compressor mounting bolt (44), the washer and nut. Carefully lift the air conditioning compressor from the engine, and lay it to the side, out of the way. 28. Disconnect fuel hose assemblies (45) and (46). Put plugs in the ends of the hose assemblies to prevent fuel loss and to keep dirt out of the fuel system. 29. Disconnect pressure switch electrical connector (47). 30. Remove two tie wraps (48) from the wiring harness for the engine speed senor. Disconnect wiring harness (49). 31. Fasten Tool (A) and a hoist to the engine as shown.32. Remove four engine mounting bolts (50) that hold the engine to the frame of the machine.
Prior to removing the engine and main hydraulic pump from the machine, make sure all hose assemblies, tube assemblies and wires have been disconnected properly.
33. Carefully remove engine and main hydraulic pump (51), as a unit, from the machine. The combined weight of the engine and main hydraulic pump is 816 kg (1800 lb). 34. Remove two mounting bolts (52) and front engine mounting bracket (53). Remove the other front engine mounting bracket. 35. Remove two mounting bolts (54) and rear engine mounting bracket (55). Remove the other rear engine mounting bracket. The following steps are for the installation of the engine and main hydraulic pump.
Visually check the condition of the rubber mounts in the front and rear engine mounting brackets. If the rubber mounts are worn or damaged or appear to be compressed, use new parts for replacement.
36. Check the condition of all O-ring seals used in the ends of the hose assemblies and tube assemblies that connect at the engine or the main hydraulic pump. If any of the seals are worn or damaged, use new parts