865078 Mercruiser SEAL, Thermostat

Start By:
Remove the bottom guards. Refer to the appropriate machine systems Disassembly and Assembly, "Bottom Guards - Remove and Install".
Remove the engine side guards. Refer to Disassembly and Assembly, "Engine Side Guards - Remove and Install".
Remove the hood. Refer to Disassembly and Assembly, "Hood - Remove and Install".
Tilt the radiator guard. Refer to Disassembly and Assembly, "Radiator Guard - Remove".
Remove the fan drive pumps. Refer to the appropriate machine systems Disassembly and Assembly, "Fan Drive Pump (Fixed Displacement, Rear) - Remove". Refer to the appropriate machine systems Disassembly and Assembly, "Fan Drive Pump (Variable Displacement, Front) - Remove".
Remove the auxiliary drive shaft. Refer to the appropriate machine systems Disassembly and Assembly, "Auxillary Hydraulic Pump Drive Shaft - Remove and Install".
Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publications Service Manuals, SENR3334, SENR5664, and NEDG5065 for the proper procedure, the proper equipment, and the proper tools needed in order to reclaim refrigerant from any Caterpillar equipment.
Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.
Note: For purging and charging the air conditioner system, refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the correct tools.
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.
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 the skin and eyes to prevent personal injury.
Personal injury can result from hydraulic oil pressure and hot oil.Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.
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.
Evacuate the air conditioning system.
Illustration 1 g00583969
Remove bolts (1) and remove both support assemblies (2) from the firewall.
Illustration 2 g00583970
Remove bolts (3) and reposition air conditioner condenser (4) aside in order to prevent possible damage.
Illustration 3 g00583971
Disconnect hose assemblies (5) from the power train oil cooler.
Illustration 4 g00583972
Disconnect hose assembly (6) .
Remove hose brackets (7) from the side of the engine.
Remove air conditioner accumulator (8) from the side of the engine.
Disconnect hose assemblies (9) from the air conditioning compressor.
Illustration 5 g00583973
Turn the heater hose valves to the Off position and disconnect heater hose (10) .
Illustration 6 g00355678
Turn off the fuel supply at the fuel tank and disconnect fuel lines (11