811636 1 Mercruiser ROTOR

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     208-5040     Support Tube     1    
189-0411 Shackle As     1    
1U-9200 Lever Puller Hoist     1    
4C-8359 Eyebolt (M12)     1    
B     6U-6145     Load Leveler     1    Start By:
Prepare the machine for disassembly and assembly procedures. For additional information, refer to Disassembly and Assembly, "Preparation for Disassembly".
Open the hood. For additional information, refer to Operation and Maintenance Manual, "Hood Tilt".
Deactivate the electrical system. Refer to Operation and Maintenance Manual, "Battery Disconnect Switch" in order to deactivate the electrical system.
Drain the cooling system. The capacity of the cooling system is 50 L (13.2 US gal). Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for more information about draining the cooling system.
Remove the fan and the fan adapter. Refer to Disassembly and Assembly, "Fan - Remove and Install".
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. 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 cooling system pressure cap is cool enough to touch with your bare hand.Remove the cooling system pressure cap slowly to relieve pressure.Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
Personal injury can result from contact with refrigerant.Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area.Personal injury or death can result from inhaling refrigerant through a lit cigarette.Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death.Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
Recover the air conditioner refrigerant from the air conditioner system.Reference: Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant"Reference: Special Publication, NEDG5065, "Air Conditioning Tools"
Illustration 1 g00804381
Remove nine bolts (1) and the washers. Remove two access panels (2) under the engine.
Illustration 2 g00804551
Disconnect three electrical connectors (3) that are located underneath the engine.
Illustration 3 g00834151
Remove nut (4) and the washer. Then, remove wire harness (5) from the support bracket.
Illustration 4 g00804583
Disconnect wire (6) from the electric starting motor. Loosen the bolt in clip (8) and remove wire (6) from clip (8). Disconnect ground strap (7) from the frame.
Illustration 5 g00804590
Loosen the hose clamp and disconnect hose (9) from the water pump.