811487 Mercruiser PLUG ANODE

1. Loosen bolts (1) and open door. 2. Remove bolts (2) and then close the door. 3. Lay the radiator assembly down flat.4. Remove tubes and hoses (3). 5. Remove mounting bolts (4). Remove fan baffles (5). 6. Fasten tooling (A) and a hoist to the radiator core. Remove the remainder of bolts (4). Remove radiator core from the radiator guard. 7. Remove bolts (7) that hold tank assembly (6) in position, and remove the tank assembly. 8. Remove four seals (8) from tank assembly (6). 9. Remove two bolts (11) that hold core assembly (9) to two straps (12) (one on each side of the core assembly).10. Loosen two bolts (10) that hold the other end of straps (12). Move the straps away from core assembly (9). Remove the core assembly.11. Repeat Steps 8 and 9 to remove the remaining core assemblies. 12. Remove seals (13) from the bottom of the core assemblies.Assemble Radiator
1. Make sure the core assemblies and the holes in the bottom tank are clean and free of dirt and foreign material.2. Lightly lubricate the inside diameter and the sealing surfaces of the seals, the bottom tank and the core assemblies with liquid soap. There are two different seals used on the top and bottom of the core assemblies. The distance between the projections on each end of the core assemblies is different. Make sure the correct seal is installed on each end of the core assemblies. 3. Install the correct seals (1) on the bottom of core assembly (2).4. Put core assembly (2) in position on the bottom tank assembly with locating projections (4) aligned with locating holes (3) in the bottom tank assembly. 5. Put straps (7) in position on core assembly (2), and install bolts (6) and (5). Do not tighten the bolts at this time.6. Inspect the seals to make sure they are not damaged, pinched or folded.7. Repeat Steps 3 through 6 for the remainder of the core assemblies if they were removed. 8. Make sure the holes in the top tank are clean and free of dirt and foreign material.9. Lightly lubricate the sealing surface and the inside diameter of the seals, the top tank and the core assemblies with liquid soap.10. Install the correct seals on core assemblies (2).11. Put top tank (8) in position on the core assemblies with each core assembly aligned with the holes in the top tank.12. Install bolts (9) that hold the top tank to the side rails. Do not tighten the bolts at this time.13. Inspect the seals to be sure they are not damaged, pinched or folded.14. Adjust the gap between the edges of the core assemblies on the front side of the radiator. Adjust the core assemblies until there is 6.5 1.5 mm (.26 .06 in.) between the edges of the cores. Adjust the center core assemblies first; then work toward the baffle assemblies on each side of the radiator.15. Tighten the bolts that hold straps (7) to the core assemblies.16. Tighten bolts (9) that hold the top tank to the side rails. 17. Fasten tooling (A) and a hoist to the radiator core assembly and put it in position in the radiator guard. 18. Install fan baffles (11) and bolts (10). 19. Install tubes and hoses (12). 20. Install bolts (13) and close radiator door. 21. Tighten bolts (14).End By:a. inltall radiator and radiator guard