805900 Mercruiser VALVE COVER (STARBOARD) - W/ DECALS

Release the pressure in the cooling system by slowly loosening the filler cap on the radiator.1. Drain the coolant from the cooling system to a level below the aftercooler.2. Remove the extension tubes from the top of the muffler. 3. Remove precleaners (1) to remove panel assemblies (2) and (3) from over the top of the engine. 4. Disconnect governor linkage (4) from the governor and move the linkage out of the way of the aftercooler.5. Remove support assembly (5) from the engine. 6. Disconnect ether aid tube (6) (if so equipped) from the aftercooler cover.7. Remove the bolts to remove tube assembly (7) and pipe (8) from the aftercooler cover and the engine. 8. Remove all the fuel line brackets and dampers (9) from the aftercooler cover.9. Remove the bolts and remove aftercooler cover (10) from the engine. 10. Remove the bolts and remove elbows (11) and (12) from the aftercooler housing. 11. Pull adapters (13) and (14) from the aftercooler core and remove these from the aftercooler housing. Remove the O-ring seals from the adapters. 12. Fasten a hoist to aftercooler core (15). Remove the bolts and remove aftercooler core (15) from the aftercooler housing. The weight of the core is 29 kg (65 lb). Remove O-ring seals (16) from the aftercooler core.Install Aftercooler
1. Install O-ring seals (2) on the aftercooler core and put clean engine oil on the seals. Fasten a hoist to aftercooler core (1) and put it in position in the aftercooler housing. Install the bolts but do not tighten the bolts. 2. Install O-rings (4) on adapters (5) and put the O-ring seals for adapters (3) in place. Put adapters (3) and (5) in position in the aftercooler housing and push the adapters in position over the tubes of the aftercooler core. 3. Make sure the O-ring seals for elbow (7) are in place and put clean engine oil on the seals. Install elbows (6) and (7) and the bolts to hold these to the aftercooler housing. Tighten the bolts that hold the aftercooler core in position. 4. Put aftercooler cover (9) and the gasket in position on the aftercooler housing. Install all the bolts except the ones with the "X" mark on the head.5. Put dampers (8) and the fuel line brackets in position and install the bolts with the "X" mark to hold these in position. 6. Put tube assembly (11) and pipe (10) with their gaskets in position and install the bolts to hold these to the aftercooler housing.7. Connect ether aid tube (12) (if so equipped) to the aftercooler housing. 8. Install support assembly (14) on the engine.9. Connect governor linkage (13) to the governor. 10. Install panel assemblies (16) and (17) over the engine and install precleaners (15). Tighten the bolts and nuts that hold the precleaners to a torque of 2.03 0.6 N m (18 5 lb in).11. Install the extension tubes on the top of the mufflers.12. Fill radiator with coolant. See Operation & Maintenance Manual for the proper procedure and levels.