5641500LP Mercruiser STERNDRIVE UNIT COMPLETE (2.20:1 Ratio)

Inspect Tubes, Hoses, Bellows, and Clamps
Inspect all tubes and hoses for leaks that are caused by the following conditions. Replace any tube or hose which exhibits any of the following conditions. Failure to replace a tube or hose which exhibits any of the following conditions may result in a hazardous situation.
Hoses which are cracked
Hoses which are soft
Outer covering that is chafed or cut
Exposed wire that is used for reinforcement
Outer covering that is ballooning locally
Flexible part of the hose that is kinked or crushed
Armoring that is embedded in the outer covering
Exhaust bellows for leaks or damage
Hoses which exhibit signs of leakage which are not the result of loose couplings or clampsInspect all clamps for the following conditions. Replace any clamp which exhibits signs of any of the following conditions.
Cracking
Looseness
DamageInspect all couplings for leaks. Replace any coupling which exhibits signs of leaks.Each installation application can be different. The differences depend on the following factors:
Type of hose
Type of fitting material
Anticipated expansion and contraction of the hose
Anticipated expansion and contraction of the fittingsDue to extreme temperature changes, the hose will heat set. Heat setting causes hose clamps to loosen which can result in leaks. A constant torque hose clamp will help to prevent loose hose clamps.Replace hoses that are cracked or soft. Replace hoses that show signs of leakage. Replace hoses that show signs of damage. Replace hose clamps that are cracked or damaged. Tighten or replace hose clamps which are loose.Replace the Hoses and the Clamps
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, "Cat Dealer Service Tool Catalog" or refer to Special Publication, PECJ0003, "Cat Shop Supplies and Tools Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.Dispose of all fluids according to local regulations and mandates.
Cooling System
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.
Personal injury can result from removing hoses or fittings in a pressure system.Failure to relieve pressure can cause personal injury.Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.
Stop the engine.
Allow the engine to cool.
Before servicing a coolant hose, slowly loosen the filler cap for the cooling system to relieve any pressure.
Remove the filler cap for the cooling system.
Drain the coolant from the cooling system to a level that is below the hose that is being replaced. Drain the coolant into a suitable clean container. The coolant can be reused.
Remove the hose clamps.
Disconnect the old hose.
Replace the old hose with a new hose.
Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications, SENR3130, "Torque Specifications", "Hose Clamps" for information about selecting and installing the proper hose clamps.
Refill the cooling system.
Clean the coolant filler cap. Inspect the gaskets on the filler cap. Inspect the gasket seat. Inspect the vacuum valve and seat for debris or damage. Replace the filler cap if the gaskets are damaged. Install the filler cap.
Start the engine. Inspect the cooling system for leaks.Fuel System
Personal injury can result from removing hoses or fittings in a pressure system.Failure to relieve pressure can cause personal injury.Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque.
Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over any disconnected fuel system components.
Note: High-pressure fuel lines may be installed between the high-pressure fuel pump and the fuel injectors. High-pressure fuel lines are constantly charged with high pressure. Do not check the high-pressure fuel lines with the engine or the starting motor in operation. Wait for 10 minutes after the engine stops before you perform any service or repair on high-pressure fuel lines. Waiting for 10 minutes will allow the pressure to be purged.
Drain the fuel from the fuel system to a level that is below the hose that is being replaced.
Remove the hose clamps.
Disconnect the old hose.Note: When servicing fuel system, use cap/s or cover/s as required to protect the system and maintain fuel system cleanliness.
Replace the old hose with a new hose.
Install hose clamps which have been inspected or install new hose clamps. Refer to Specifications, SENR3130, "Torque Specifications", "Hose Clamps" for information about selecting and installing the proper hose clamps.
Carefully inspect the engine for any spilled fuel. Make sure that no fuel remains on or close to the engine.Note: Fuel must be added to the fuel system ahead of the fuel filter.
Refill the fuel system. Refer to this Operation and Maintenance Manual, "Fuel System - Prime" for information about priming the engine with fuel.
Start the engine. Inspect the fuel system for leaks.