99160 Mercury BOOT, OIL TANK (UPPER)

1. Drain the coolant from the cooling system. Use caution to avoid spilling coolant on exhaust manifolds and shields. 2. Remove four bolts (1) holding the flanges on the right hand air pipe (4). 3. Attach a strap to the air pipe and remove one bolt (2) and one clamp (3). Remove air pipe (4). Weight of air pipe is 20 kg (45 lb). Strap is necessary due to the fact that the pipe is awkward. 4. Remove four bolts (5) holding the flanges on the left hand air pipe (6). Remove air pipe (6). 5. Remove four bolts (7) from the front water elbow.6. Remove two bolts (9) holding the flange on the water pipe (10). Remove the front elbow (8) and remove water pipe (10).7. Note the condition of the O-rings on the end of water pipe (10). If necessary replace prior to installation. 8. Remove four bolts (11) from the rear water elbow.9. Remove two bolts (13) holding the flange on the water pipe (14). Remove the rear elbow (12). It is not necessary to remove water Pipe (14).10. Note the condition of the O-rings on the end of water pipe (14). If necessary replace prior to installation. 11. Remove four nuts and bolts and four other bolts (15) and remove two brackets (16). 12. Remove metal line (17).13. Remove six bolts (19) holding the flanges on water pipe (20), water connector (18) and the two sections of the aftercooler.14. Remove water connector (18) from between the aftercoolers.15. Remove bolt and clamp (21) and water pipe (20)16. Note the condition of the O-rings on the end of water pipe (20). If necessary replace prior to installation. 17. Remove thirty bolts (22) from each exhaust manifold heat shroud (23). Remove manifold head shroud (23) from each side of the engine. 18. Loosen three clamps (24), loosen connectors and remove pipe (25). 19. Remove the remaining bolts (26) holding the aftercoolers to the engine. They are located under each of the water elbows and the water connector. 20. Check to insure that all bolts have been removed from the aftercoolers. Attach tooling (A) to the top of each aftercooler and slowly remove each of the aftercoolers. Weight of each of the aftercoolers is 69 kg (152 lb).
Be careful when removing the aftercoolers to prevent damage to the exposed underside of the aftercoolers.
21. Carefully clean any gasket material from the base of the aftercoolers and the air intake manifold. Remove any particles from the air intake manifold to insure that they will not get into a cylinder. Replace with new gaskets. Installation is accomplished in the exact reverse order from removal.22. Clean and inspect all of the O-ring seals and gaskets. Make a replacement of any worn or damaged seals and gaskets. Put clean engine oil on all O-ring seals prior to installation.23. Tighten the aftercooler bolts to a torque of 55 7 N m (41 5 lb ft).24. Fill the cooling system with coolant to the correct level. See the Maintenance Manual for the correct fluid level.