897593T02 Mercury CHAP ASSEMBLY, Starboard and Port

Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2 Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry the parts. Lint may be deposited on the parts which may cause later trouble.Note: Inspect all the components of the radiator for wear or for damage. Replace the components, if necessary.Note: Rinse the inside of bottom tank (16) thoroughly after the tank is cleaned. This will help to prevent contamination of the cooling system.
Illustration 1 g00573172
Position bottom tank (16), as shown. The weight of bottom tank (16) is 64 kg (141 lb). Use a suitable lifting device and a hoist in order to position channel (22) for installation to bottom tank (16). Install channel (22) to bottom tank (16) with four bolts (23), the washers, four bolts (24) and the washers. The weight of channel (22) is 47 kg (104 lb).
Repeat Step 1 for the remaining channel (22).
Illustration 2 g00573792
Install shield (21) with five bolts (20) and the washers. Repeat the installation for the remaining three shields (21).
Install strip (18) and baffle (19) (not shown) with four bolts (17) and the washers. Repeat the installation for the remaining three strips (18). Tighten bolts (17) to a torque of 8 4 N m (6 3 lb ft).
Illustration 3 g00573170Note: Lubricate seals (14) and seals (15) with 5P-3975 Rubber Lubricant prior to installation.
Install thirteen seals (14) and thirteen seals (15) to bottom tank (16).
Illustration 4 g00573193Note: Lubricate the bores of the seals with 5P-3975 Rubber Lubricant before the radiator cores are installed.Note: For installation purposes, assemble straps (12) to 13 radiator cores (13). Start with the radiator core at each channel and install the radiator cores toward the center of the radiator assembly. Install the radiator cores by alternating with the remaining thirteen radiator cores without straps (12).
Illustration 5 g00572201
Before bolts (11) are tightened, adjust gap (X) at the front of the radiator to 6.5 mm (0.25 inch). Before bolts (11) are tightened, adjust gap (Y) at the back of the radiator to 2.0 1.5 mm (0.08 0.06 inch).
Illustration 6 g00573194
Illustration 7 g00573195
Install 26 radiator cores (13). Assemble 31 bolts (11), the washers and 31 straps (12) to the upper tabs and the lower tabs on the front of 13 radiator cores (13). Repeat the assembly for the remaining tabs on the back of 13 radiator cores (13).
Illustration 8 g00569195
Install 31 bolts (11) to the upper tabs and the lower tabs on the front of the radiator cores. Repeat the installation for the remaining tabs on the back of the radiator cores.
Illustration 9 g00573168
Install front strap (9) to the angles with four bolts (10) and the washers.
Illustration 10 g00573166
Install 26 bolts (8) and the washers that secure the radiator cores to front strap (9).
Illustration 11 g00573165Note: Rinse the inside of top tank (1) thoroughly after the top tank is cleaned. This will help to prevent contamination of the cooling system.Note: Lubricate seals (7) with 5P-397