811407 Mercruiser WASHER

1. Disconnect three electrical connectors (2). Remove one bolt and washer (hidden) holding wiring harness clamp to flywheel housing.2. Disconnect and cap fuel line (1). 3. Remove two support clamps (4). Disconnect and cap fuel line (3). 4. Remove nut and washer (6) and disconnect two ground wires (7).5. Disconnect two wires to starter solenoid (5). 6. Remove nut (8) and plastic cover (9).7. Disconnect solenoid wire (10). 8. Disconnect cold starting aid tube (14).9. Remove wire tie wrap (12) and support clamp (13).10. Disconnect wiring harness (11).
At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the hydraulic system before and hydraulic lines or components are disconnected or removed.
11. Disconnect two tube assemblies (15). 12. Remove two bolts and washers (16) and remove hydraulic oil cooler (17). 13. Remove two bolts and washers (19) and disconnect alternator wire (18).14. Disconnect hose assembly (20). 15. Remove four bolts and washers (22) and remove two clamps (23).16. Slide exhaust tube (21) towards muffler.17. Loosen two clamps (24). 18. Remove eight bolts and washers (27) and disconnect two hose assemblies (25). Remove bolt and clamp (26). 19. Remove four bolts and washers (29) connecting drive shaft (28) to transmission yoke (30). 20. Disconnect heater hose assembly (33).
Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publication SENR3334-01, SENR5664 and NEDG5065-01 for the 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 R-12 (CCI2F2 Dichlorodifluoromethane) or refrigerant R-134A can cause freezing of human flesh.Do not smoke while working on air conditioning systems. INHALING REFRIGERANT R-12 OR REFRIGERANT R-134A 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 and SENR5664, for more information on removal and installation of lines and refrigerant from the system.
21. Purge the air conditioning system. See the topic "Purging the System" in the Air Conditioning and Heating Service Manual, Form No. SENR3334 or SENR5664 for the correct procedure.22. Disconnect two refrigerant hose assemblies (31). Remove two support clamps (34).23. Support the engine (32) with hoist and appropriate lifting device.24. Remove four mounting bolts (35) along with the upper half of mounting assemblies (36).25. Remove engine (32). The weight of the engine is 1000 kg (2200 lb). The following steps are for the installation of the engine. 26. Position four lower half mounting assemblies (37) in the machine frame. 27. Align the slots in transmission yoke (38) to approximately match the locating tabs on the universal joint of drive shaft (28). 28. Position four bolts and washers (35) and upper half mounting assemblies (36) in the matching engine supports.29. Position the engine in the machine frame. Align bolts and washers (35) into lower mounting assemblies (37) as the engine is lowered into position.30. Install the washers and nuts onto four bolts (35). Remove the hoist and lifting device.31. Align the tabs on drive shaft (28) with the slots in transmission yoke (38), and install four bolts and washers (29). Tighten four bolts (29) to a torque of 135 20 N m (100 15 lb ft).32. Connect heater hose assemblies (33).33. Connect two hose assemblies (25). Install bolt and support clamp (26).34. Connect muffler and air cleaner assemblies.35. Connect hose assembly (20).36. Install two bolts and washers (19) and connect alternator wire (18).37. Install hydraulic oil cooler (17). Connect two tube assemblies (15).38. Install wire tie wrap (12) and support clamp (13), and connect wiring harness (11).39. Connect cold starting aid tube (14). If the refrigerant compressor was set aside while removing the engine, reposition the compressor and install the belt and bolts. If refrigerant lines (31) were removed from the compressor, connect lines (31). See the topic "Complete Charging of the System" in the Air Conditioning and Heat Service Manual, Form No. SENR3334-01 or SENR5664 for the correct procedure to charge the system.
Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publication SENR3334-01, SENR5664 and NEDG5065-01 for the 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 R-12 (CCI2F2 Dichlorodifluoromethane) or refrigerant R-134A can cause freezing of human flesh.Do not smoke while working on air conditioning systems. INHALING REFRIGERANT R-12 OR REFRIGERANT R-134A 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 and SENR5664, for more information on removal and installation of lines and refrigerant from the system.
40. Connect refrigerant lines (31) and install support clamps (34). Charge the air conditioning system.41. Connect solenoid wire (10). Install plastic cover (9) and nut (8).42. Connect two wires to starter solenoid (5).43. Connect two ground wires (7) and secure with nut and washer (6).44. Install two support clamps (4). Connect fuel line (3)