91964 Mercruiser WASHER

At operation 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 from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
Release the pressure in the cooling system by slowly loosening the filler cap on the radiator. Drain the coolant from the radiator and oil from the hydraulic oil cooler.
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.
Release the pressure in the hydraulic system as follows: a. shut off the engine.b. Move the control levers through their full travel strokes. This will relieve any pressure that may be present in the pilot system.c. Slowly loosen the air breather cap on the hydraulic oil tank to release the pressure.d. Tighten the air breather cap on the hydraulic oil tank.e. The pressure in the hydraulic system has now been released. Lines and components can now be removed.
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 (C C12 F2 Dichloro Difluoro Methane) and refrigerant R-134A can cause freezing of human flesh. Do not smoke while working on air conditioning. Inhaling Refrigerant R-12 or R-134A through any smoking material, although not toxic or flammable, can cause violent illness. 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.
Release the refrigerant R-12 from the system. See Air Conditioning And Heating, Purging The System, Form No. SENR3334-01. 1. Disconnect wiring harness (4). Disconnect line (1), remove two nuts (2) and remove ether starting aid (3). 2. Remove bolts and washers (5), remove bolt and washer (6) that holds wiring harness (4) to side guard (7) and remove the side guard (both sides). 3. Remove bolts and washers (8) on both sides. Remove both sides of sheet metal (9). 4. Remove bolts and washers (10) and remove L-Brackets (11) from sheet metal (12). 5. Remove bracket (13) that holds cable (14) to sheet metal (12). Remove bolts (15) that holds the sheet metal. 6. Disconnect cable (14) from the injection pump and pull through the sheet metal. 7. Disconnect three hydraulic lines (16), so the sheet metal can be pulled free. 8. Disconnect all hydraulic lines (17) that are connect to the pump. 9. Remove two hose clamps (18), two bolts, washers, nuts and clamps (19). Remove breather tube (20). 10. Remove two bolt (21) and remove pump (22). Step 10 must be done for access of lines on the other pump. 11. Remove bolts and washers (23) and remove back engine mounts (24). 12. Secure with straps and hoist and remove bolts and remove drive shaft (25). 13. Disconnect wiring harness (26) and all the hydraulic lines under the pumps. 14. Disconnect two water lines (28) and two priming pump lines (27). 15. Disconnect wires (29) on the starter and hose (30). 16. Disconnect wiring harness (32) from alternator. Remove bolts (33) and brackets, disconnect air conditions line (31). 17. Disconnect bracket (not shown) from drain line (34). This line will be removed with the engine. 18. Remove the bolts, washers and nuts on front motor mounts (35). 19. Attach hoist and chains as shown to the engine. Pull the engine forward and then up for removal. Place on suitable supports when removed. The weight of the engine and the torque converter 3859 kg (8500 lb). Install in the reverse order.End By:a. install hoodb. install radiator guard See Air Conditioning And Heating Service Manual, Form No. SENR3334 for the correct procedure to charge the system. Fill radiator with coolant. See Operation & Maintenance Manual for the proper procedure and levels. Fill hydraulic tank with hydraulic oil. See Operation & Maintenance Manual for the proper procedure and levels.