85500 Mercruiser PIN, Dowel (.187 x .530), GEAR HOUSING TO DRIVESHAFT HOUSING

Start By:a. remove crankcase guards (rear only)
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 filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
1. Release the pressure in the cooling system by slowly loosening the filler cap on the radiator. Drain the coolant from the radiator into a suitable container for storage or disposal. The capacity of the cooling system is 135 liters (35.1 U.S. gal). 2. Open the engine enclosure doors on each side of the engine.3. Remove six bolts (2) and the washers that hold hood (1) in position. Fasten a hoist to the hood, and remove it from the machine. The weight of the hood is 45 kg (100 lb). 4. Loosen two clamps (3). Slide hose (4) off of the tube assembly that is connected to the radiator top tank. 5. Loosen clamp (9).6. Remove four bolts (5) and the washers. Remove four bolts (7) and the washers.7. Remove tube assemblies (6) and (8) from the radiator top tank.
View From Under Radiator8. Remove four bolts (10) and the washers that hold the tube assembly to the bottom of the radiator.9. Remove eight bolts (11), the washers and guard (12).
View From Right Side Of Radiator10. Remove four bolts (13), the washers and shield (14).
Do not damaged the radiator when it is being removed or installed in the radiator guard.
11. Fasten tool (A) and a hoist to the top of radiator (15) as shown.12. Remove sixteen bolts (16) and the washers that hold the radiator is position. Carefully remove radiator (15) from the radiator guard. The weight of the radiator is 243 kg (535 lb). The following steps are for the installation of the radiator.13. Fasten tool (A) and a hoist to the top of radiator (15). Carefully lower the radiator into position in the radiator guard.14. Install sixteen bolts (16) and the washers that hold the radiator in position.15. Reinstall shield (14) and four bolts (13) that hold it.16. Reinstall guard (12), the washers and bolts (11) that hold the guard.17. Reconnect the tube assembly at the bottom of the radiator using the washers and bolts (10).18. Connect tube assemblies (6) and (8) to the radiator top tank using bolts (5), (7) and the washers.19. Connect the short hose to tube assembly (8) using clamp (9).20. Slide hose (4) onto the tube assembly that is connected to the radiator top tank. Install two clamps (3) to hold the hose in position.21. Reinstall hood (1) on the machine using six bolts (2) and the washers to hold it.22. Fill the cooling system with coolant to the correct level. See the Operation & Maintenance Manual for the correct filling procedure.23. Prior to installation of the rear crankcase guard, start the machine, and check for coolant leaks.End By:a. install crankcase guards (rear only)