808102 Mercruiser PLUG (13/16" CUP)

1. Loosen nut (1) on the adjusting rod to loosen the tension on the V-belts. Remove V-belts (2) from the pulley on the alternator.
Do not cause damage to the radiator core when the fan assembly and adapter are placed against the radiator core for removal of the fan drive.
2. Fasten a hoist to fan assembly and adapter (3) as shown. Remove the six nuts and washers that hold the fan assembly and adapter to the fan pulley. Carefully place the fan assembly and adapter against the radiator core. 3. Fasten a hoist to fan pulley and fan drive (4) as shown. Remove the eight bolts that hold the fan drive to the cylinder head assembly and support bracket (5). Remove the fan pulley and fan drive as a unit. The weight of the unit is 43 kg (95 lb). The following steps are for the installation of the fan drive.4. Fasten a hoist to fan pulley and fan drive (4). Put the unit in position on the front of the cylinder head assembly and support bracket (5) as shown. Install the four bolts that hold it. Be sure the V-belts are in position on the fan pulley.5. Fasten a hoist to the fan assembly and adapter (3). Put the unit in position on the fan pulley, and install the six washers and nuts that hold it.6. Install two V-belts (2) in the pulley on the alternator. Adjust the V-belt tension. See "Fan and Alternator Belts" in the Operation & Maintenance Manual.Disassemble Fan Drive
Start By:a. remove fan drive 1. Remove two bolts (1) and retaining washer (3) from the end of the shaft in the fan bracket.2. Remove pulley (4), the spacer and hub (2) from fan bracket (5) as a unit. 3. Remove front bearing (6) from the hub (2). Remove the pulley from the hub. Rear bearing (7), and seal (8) may have stayed with pulley (4) when it was removed from the fan shaft.4. Remove rear bearing (7) and seal (8) from fan bracket (5).5. Remove the spacer from the fan bracket.Assemble Fan Drive
1. Be sure all parts of the fan drive are thoroughly clean and free of dirt and debris. Also, hand pack the bearings in the fan drive with 5P0960 Multipurpose Grease prior to assembly. The pulley must be installed on the hub with the spacer down against the shoulder of the hub.2. Install pulley (1) on hub (2) as shown.3. Install the rear bearing in the hub4. Using tool (A), install seal (4) in the hub. Install the seal until it is even with the outside of the hub and with the lip of the seal facing out as shown. Put a thin coat of 5P0960 Multipurpose Grease on the lip of the seal. 5. Install spacer (3) in seal (4). Be sure four mounting bolts (7) are installed in the fan bracket prior to installation of the pulley on the fan bracket.6. Put pulley and hub assembly (5) on fan bracket (6). 7. Install spacer (8) over the shaft of the fan bracket. 8. Install front bearing (9) in the hub until it makes contact with the counterbore in the hub. 9. Put retaining washer (10) in position on the end of the shaft of the fan bracket. Install the two bolts that hold the fan drive unit together.End By:a. install fan drive