91000 2 Mercruiser STUD

Start By:a. remove hoodb. remove crankcase guards1. Lower the bucket of the machine to the floor.2. Activate the parking brake.3. Connect the steering frame lock link. See the topic "Separate & Connect Steering Frame Lock Link" in the Power Train Disassembly & Assembly module, Form No. SENR5729.4. Release the pressure in the hydraulic system as follows: a. Move the lift control lever to the "Float" position.b. Shut off the engine.c. Move the lift control lever to the "Hold" position.
At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. Remove the filler cap on the hydraulic oil tank only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Be sure all the hydraulic pressure is released before any fittings, hoses or components are loosened, tightened, removed or adjusted.
d. Carefully loosen the filler cap on the hydraulic oil tank to release the pressure.e. Carefully loosen the plugs at the rear of the tilt cylinders. When the oil from the loosened plugs stops draining, tighten the two plugs.f. Tighten the filler cap on the hydraulic oil tank.g. The pressure in the hydraulic system has now been released.5. Drain the oil from the hydraulic oil tank into a suitable container for storage or disposal. The capacity of the hydraulic oil tank is 235 liters (61.1 U.S. gal).
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.
6. 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 135 liters (35.1 U.S. gal).7. Remove the muffler and air cleaner assembly from the machine. See the topics "Muffler" and "Air Cleaner Assembly" in this module. 8. Open two engine access doors (1).9. Remove twenty four bolts (3) and two covers (4).10. Remove two doors (2). 11. Disconnect wire (5) for the ether starting aid.12. Disconnect tube assembly (6) for the ether starting aid. 13. Disconnect wiring harnesses (7), (8) and (9) from the relay panel.14. Fasten lifting straps and a hoist to frame (11) as shown. Remove two bolts (10) and the washer that hold the frame in position. Remove the frame. The weight of frame (11) is 43 kg (95 lb). 15. Disconnect tube assemblies (12) and (13) from the fuel filter base on the left rear side of the engine. 16. Disconnect two fuel lines (16) and (17).17. Fasten lifting straps and a hoist to frame (15) as shown. Remove two bolts (14) and the washers that hold the frame. Remove the frame from the machine. The weight of frame (15) is 36 kg (80 lb). 18. Remove bolt (18) and torque converter control cable (19) from the sequence and pressure control valve.19. Disconnect hose assembly (20) and wire harness (21) from the sequence and pressure control valve. Remove all clips (22) that hold the wire harness to the engine. 20. Disconnect wire assembly (23), and remove clip (24) from the torque converter outlet relief valve.
View From Under Engine21. Remove bolt (25) and the clamp.
Regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publication SENR3334-01 and NEDG5065-01 for proper procedure, 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.
22. Release the Refrigerant-12 from the system.
View From Under Engine23. Disconnect hose assemblies (26) and (27) from the refrigerant compressor.24. Disconnect hose assemblies (28) and (29) from the engine oil cooler.
View From Under Engine25. Disconnect hose assembly (30). 26. Disconnect heater hose assemblies (31) and (32).27. Disconnect hose assemblies (33) and (34) from the fan drive pump.28. Loosen clamp (35) to disconnect the tube assembly that is routed to the bottom of the radiator.29. Remove bolt (36) and the nut. 30. Loosen two hose clamps (37). Separate tube assembly (38) from the tube assembly that is fastened to the radiator top tank. 31. Loosen two hose clamps (39). Separate tube assembly (40) from the tube assembly that is fastened to the radiator top tank.32. Disconnect hose assembly (41) from the fan drive pump. 33. Disconnect wire connectors (42) and (43).34. Put identification marks on six wires (44) that are connected to the electric starting motor for installation purposes. Disconnect the six wires from the electric starting motor. 35. Disconnect wire harness (46). Remove two bolts (45) from the front engine support. 36. Remove two clips (47). Disconnect wire harness (48) from the engine oil filter base sending unit. 37. Disconnect two hose assemblies (49) from the engine oil filter base. 38. Disconnect three hose assemblies (50) from the engine oil filter base. 39. Remove both engine oil filters and engine oil filter bases (51). 40. Loosen two hose clamps (52).41. Remove eight bolts (53) and two tube assemblies (54) at the rear of the engine. 42. Remove two bolts (55) and bracket (56). 43. Remove eight bolts (57) and shield assembly (58). 44. Disconnect governor control cable (59).45. Disconnect tube assembly (60) from the transmission oil pump.46. Disconnect hose assembly (61) from the transmission oil pump.