808489 Mercruiser WASHER

1. Remove engine compartment doors. Remove six bolts (1) and remove side covers, (both sides). 2. Remove the engine hood 40.9 kg (90 lbs.).3. Remove bolts (2) and remove radiator guard. 4. Drain coolant and remove hose (3) from bottom of radiator. 5. Remove eight bolts (4) and remove hydraulic lines. Remove bolt (5) and clip. 6. Remove hose (6) from top of radiator. Remove bolts (7) and remove top half of fan guard. 7. Disconnect air conditioner line at pressure sealed connection (8), (this should prevent freon from being lost). 8. Fasten a sling around the fan hub and to a hoist. Remove six bolts (9) and remove the fan blade. The fan blade weighs 45 kg (100 lbs.). 9. Remove bolt (10) from inside of frame. 10. Fasten a sling to cylinder trunions from the hoist. 11. Install tooling (A) or (B). Remove rear pins from frame and radiator guard. To remove the bolt, reach through the track. 12. Install ratchet puller tooling (C) from cab lifting eye to the side of radiator guard, using tooling (D). Tilt radiator guard forward. Tilting force forward is 204 kg (450 lbs.) in the position shown.Tilt Radiator Guard Backward (D6H)
Tilting force forward is 204 kg (450 lbs.) in position shown.1. Install ratchet puller tool (C) from cab lifting eye to the side of radiator guard. Also install sling and hoist to the cylinder trunions on the radiator guard. Tilt the radiator guard back.2. Position guard and install the rear pins in the frame and radiator guard. 3. Install bolt (10) inside frame. 4. Fasten sling around fan hub to hoist, position fan blade and install bolts (9). 5. Connect air conditioner line, a pressure sealed connection (8). 6. Position top half of fan guard and install bolts (7). Connect hose (6) at the top of the radiator. 7. Position clip and install bolt (5), position hydraulic lines and install bolts (4). 8. Install hose (3) at the bottom of the radiator, and fill the radiator with coolant. See the Maintenance Guide. 9. Position radiator guard and install bolts (2). 10. Install engine hood, weight is 40.9 kg (90 lbs.).11. Position engine side covers (both sides) and install bolts (1). Tilt Radiator Guard Forward (D7H)
Start By: a. remove fan and fan drive1. Remove clamps, hose (1) and tube (2). 2. Remove bolt and clip (3). Disconnect the harness at connector (4). 3. Remove four bolts and remove guard (5), using a hoist. Guard weight is 52.2 kg (115 lbs.). 4. Disconnect quick couplings (6). Remove bolt and clip (7). 5. Remove bolt and clip, holding two air conditioner lines.6. Install tooling (A) and a hoist to support the radiator. 7. Remove bolt holding clip (8) and hose to the bottom of radiator. Remove two bolts (9) and bracket holding two hoses to the frame.8. Remove bolt (10), washer and nut (both sides). 9. Install tooling (B) and remove pin (both sides). 10. Tilt radiator forward using a hoist. Tilt Radiator Guard Backward (D7H)
1. Fasten a hoist to the radiator guard. 2. Install pin in both sides of the radiator guard, and install bolts (10). Remove hoist and tooling. 3. Position hose and bracket to the frame and install bolts (9). Position hose and install clip (8) to hold hose to the bottom of the radiator.4. Install bolt and clip holding two air conditioner lines.5. Connect quick coupling (6) and install bolt and clip (7). 6. Fasten a hoist and position guard (5) and install bolts. 7. Connect harness at connector (4), and install bolt and clip (3). 8. Install tube (2) hose (1) and clamps. End By: a. install fan and fan drive