815953 Mercruiser PIN

At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Drain the coolant 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 avoid personal injury.
1. Position a suitable container under the radiator. Loosen the radiator cap from the tank assembly. Remove the drain plug from the plug adapter, and drain the radiator below the level of the expansion tank assembly. The capacity of the cooling system is 142 L (37 U.S. gal). For more information, refer to the topic "Drain And Refill Radiator" in this manual. 2. Loosen clamp (3) and disconnect hose (2) from tank assembly (1). 3. Loosen two hose clamps (4) and (5). Disconnect two hoses (6) and (7) from tank assembly (1). 4. Remove two bolts (9) and the washers from grate (8). 5. Remove left hand door assemblies (10), (11), (12) and (13) from the engine enclosure from the left side of the machine only. 6. Remove bolt (14), the washer, and left hand door assembly (15) from the engine enclosure. 7. Remove bolt (18), the washer, spacer (19), and rubber strip (16) from shield assembly (17). 8. Remove four bolts (21) and the washers from left hand tube assemblies (20). 9. Mark and identify two wire harnesses (22) and (24) for installation purposes. Disconnect two wire harnesses (22) and (24) from relay panel (23). 10. Remove bolt (25) and the washers from bracket (26). 11. Remove bolt (27) and the washer from bracket (28).12. Repeat Steps 10 and 11 for the remaining side.
For field removal, it is suggested, (but not required) to remove left hand tube assembly (20) from the machine prior to removing the engine enclosure. Interference with the exhaust manifold and left hand tube assembly (20) may occur while removing the engine enclosure. If left hand tube assembly (20) is not removed, proceed to Step 14.
13. Remove ten bolts (29) and the washers from left hand tube assembly (20). Using a suitable lifting device, remove left hand tube assembly (20) from the engine enclosure. The weight of left hand tube assembly (20) is 26 Kg (58 lb). 14. Remove bolt (30) and the washer from bracket (31). Remove heat shield (32) from the front hood assembly. 15. Remove two bolts (34) and the washers from left hand tube assembly (33). 16. Remove two bolts (35) and the washers from left hand tube assembly (36). 17. Remove bolt (39) and the washer from the engine enclosure. Open right hand door assemblies (37) and (38). Remove right hand door assembly (40) from the engine enclosure. 18. Remove two bolts (42) and the washers from right hand tube assembly (41). 19. Remove two bolts (42) and the washers from right hand tube assembly (43). 20. Remove two bolts (42) and the washers from right hand tube assembly (44). 21. Remove two bolts (42) and the washers from right hand tube assembly (45).
Refer to Step 13 in this procedure. If the left hand tube assembly was not removed, exercise extreme care to avoid contact with the exhaust manifold. Failure to do so could result in parts damage.
22. Position a suitable lifting device on engine enclosure (46) as shown. Secure the lifting device to a hoist. Remove engine enclosure (46) from the rear frame assembly. The weight of engine enclosure (46) is 579 Kg (1275 lb). The following steps are for the installation of the engine enclosure.23. Make sure all components of the engine enclosure are clean of dirt and foreign material prior to installation.24. Check all components for wear or damage and replace if necessary. 25. Position a suitable lifting device on engine enclosure (46) as shown. Secure the lifting device to a hoist. Put engine enclosure (46) on the rear frame assembly. The weight of engine enclosure (46) is 579 Kg (1275 lb). 26. Install two bolts (42) and the washers to right hand tube assembly (45). 27. Install two bolts (42) and the washers to right hand tube assembly (44). 28. Install two bolts (42) and the washers to right hand tube assembly (43). 29. Install two bolts (42) and the washers to right hand tube assembly (41). 30. Put right hand door assembly (40) in position on the engine enclosure. Install bolt (39), and the washer to the engine enclosure. Close right hand door assemblies (37) and (38). 31. Install two bolts (35) and the washers to left hand tube assembly (36). 32. Install two bolts (34) and the washers to left hand tube assembly (33). 33. Put heat shield (32) in position on front hood assembly. Install bolt (30), bracket (31), and the washer to the front hood assembly. 34. If removed, position a suitable lifting device on left hand tube assembly (20). Secure the lifting device to a hoist. Position left hand tube assembly (20) under the engine enclosure as shown. Install ten bolts (29) and the washers to left hand tube assembly (20). The weight of left hand tube assembly (20) is 26 Kg (58 lb). If left hand tube assembly was not removed, proceed to Step 35. 35. Install bolt (27) and the washer to bracket (28). 36. Install bolt (25) and the washer to bracket (26).37. Repeat Steps 35 and 36 for the remaining side. 38. Connect two wire harnesses (22) and (24) to relay panel (23).