95391 Mercury SCREW, FUEL TANK

1. Drain the cooling system.2. Disconnect the governor control linkage from the governor. Remove the control channel assembly mounting bolts and the assembly clear of the aftercooler.3. To remove the left aftercooler core only, remove the instrument panel mounting bolts. Move the instrument panel away from the aftercooler. 4. Remove the aftercooler air inlet elbow retaining washer and bolt from the turbocharger and disconnect equalizer line (1).5. On industrial engines only, remove the aftercooler vent line (2). Remove the four cover assembly mounting bolts. Pull the cover assembly (3) out of the housing. 6. Remove the aftercooler upper housing mounting bolts. Fasten tooling (A) and a hoist to the housing. Remove the aftercooler upper housing. Weight is 70 lb. (32 kg).7. On marine engines only, remove exhaust manifold front water outlet line. Remove the jacket water bypass line. Remove the aftercooler sea water outlet line. 8. Remove the aftercooler water inlet elbow (4). Pull the sleeve assembly (5) out of the aftercooler core. 9. Remove the aftercooler water outlet elbow mounting bolts from the rear of the aftercooler lower housing. Remove the water outlet elbow (6). Pull the sleeve assembly (7) out of the aftercooler core.10. On marine engines only, remove the sea water equalizer tube assembly from the rear of the aftercoolers. Remove the sleeve assembly.11. Fasten a hoist and remove the aftercooler core. Weight is 60 lb. (27 kg).12. Fasten tooling (A) and a hoist to the aftercooler housing. Remove the bolts that hold the housing in place and remove the housing. Weight is approximately 80 lb. (36 kg).Install Aftercooler Cores And Housings (Earlier Engine)
1. Fasten tooling (A) and a hoist to the aftercooler housing. Put the gaskets and aftercooler housing in position on the engine. Weight is approximately 80 lb. (36 kg). Install the bolts that hold the housing in place.2. Thoroughly clean the contact surfaces of the aftercooler core and the upper and lower housing.3. Install a new core-to-lower housing gasket. Fasten a hoist and install the aftercooler core into the lower housing. 4. Install the sleeve assembly (1) in the front and rear of the aftercooler lower housing.
Be sure the drain hole in the sleeve assemblies is in a down position.
5. Install the water outlet elbow on the rear of the aftercooler housing, and install mounting bolts.6. On marine engines, install the sea water rear equalizer tube assembly on to the rear of the aftercooler housings.7. Install the water inlet elbow on the front of the aftercooler housing.8. On marine engines, install the aftercooler sea water outlet line. Install the jacket water bypass line, and install the exhaust manifold front water outlet line. 9. Install a new gasket between the core and upper housing. Install two 5/16"-18 NC forged eyebolts into the upper housing. Fasten a hoist and install upper housing (2) and mounting bolts.10. Install the bolt and washer to hold the air inlet elbow on the turbocharger.11. Connect the aftercooler air equalizer line. 12. On industrial engines, install the cover assembly (3) and mounting bolts in front of aftercooler housing. Install the aftercooler vent line.13. Put the instrument panel in position on the left aftercooler housing and install the panel mounting bolts.14. Install the governor control channel assembly, spacers and mounting bolts. Connect the control linkage to the governor.15. Fill the cooling system.