808125 Mercruiser PLUG (1/8-27)

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. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
1. Release the pressure in the cooling system. Drain the coolant from the radiator into a suitable container for storage or disposal. The capacity of the cooling system is 44 liters (11.4 U.S. gal).
Regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publications SENR3334-01 and NEDG5065-01 for the proper, 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-12 (Dichlorodifluoromethane) can cause freezing of human flesh.Do not smoke while working on air conditioning systems. INHALING REFRIGERANT-12 THROUGH ANY SMOKING MATERIAL, ALTHOUGH NOT TOXIC OR FLAMMABLE CAN GENERATE LETHAL PHOSGENE GAS AND CAUSE VIOLENT ILLNESS OR DEATH. ALSO, HEAT MUST NEVER BE APPLIED TO A CHARGED SYSTEM. See Air Conditioning And Heating Service Manual, Form No. SENR3334-01, for more information on removal and installation of lines and refrigerant from the system.
2. Evacuate air conditioning system 3. Disconnect air conditioning line (1) from air conditioning condenser (3).4. Loosen the lower nut on adjusting rod (2) to loosen the tension on the V-belts. Remove V-belts (4) from the pulley on the alternator. 5. Disconnect air conditioning line (8) from air conditioning condenser (3).6. Remove two bolts (7) from both ends of air conditioning condenser (3), and remove the air conditioning condenser.7. Loosen hose clamp (9) on each end of tube (6). Loosen the hose clamp on each end of hose (5). Remove hose (5) and tube (6).
Typical Example8. Remove bolts (10) from fan guards (11). Remove two fan guard assemblies (11).
Typical Example
Do not cause damage to the radiator core when the fan assembly is removed from the machine.
9. Fasten a hoist to fan assembly (12) to support it. Remove the eight bolts and washers that hold the fan assembly to the fan adapter. Carefully place the fan assembly against the radiator core.10. Remove the six nuts and washers that hold the fan adapter to the fan pulley. Remove the fan adapter. Remove fan assembly (12). The weight of the fan assembly is 39 kg (85 lb). The following steps are for the installation of the fan assembly.11. Fasten a hoist to fan assembly (12), and put in position against the radiator core.12. Put the fan adapter in position on the fan pulley, and install the six washers and nuts that hold it.13. Put fan assembly (12) in position on the fan adapter. Install the eight bolts and washers that hold it.14. Reinstall two fan guard assemblies (11).15. Reinstall hose (5) and tube (6). Tighten the two hose clamps that hold hose (5) and two hose clamps (9) that hold tube (6).16. Put air conditioning condenser (3) in position, and install two bolts (7) at each side.17. Connect air conditioning lines (1) and (8) to the air conditioning condenser.18. Install V-belts (4) on the alternator pulley. Adjust the V-belt tension. See the topic "Fan and Alternator Belts" in the Operation & Maintenance Manual.19. Fill the cooling system with coolant to the correct level. See the Operation & Maintenance Manual for the correct filling procedure.20. Charge the air conditioning system. Refer to the Air Conditioning And Service Manual, Form No. SENR3334 for the correct procedure.End By:a. install hood