880504A12 Mercury CYLINDER BLOCK ASSEMBLY

Start By:
Remove the hood. Refer to Disassembly and Assembly, "Hood - Remove and Install". The information is in this manual.
Personal injury can result from hot coolant, steam and alkali.At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines.Dispose of all fluids according to local regulations and mandates.
Drain the coolant from the cooling system into a suitable container. The coolant system contains 38 L (9.9 US gal) of coolant.
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Loosen hose clamp (1) and disconnect hose (2) from aftercooler (3) . Loosen hose clamp (4) . Loosen hose clamp (5) and disconnect hose (6) from aftercooler (3) .
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Loosen hose clamp (7) .
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Remove nut (8) and disconnect dipstick guide tube (9) from bracket (10) .
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Remove nut (11) and disconnect cable assembly (12) from heater assembly (13) . Remove nut (14) and disconnect ground strap (15) from heater assembly (13) . Loosen retaining nut (16) and disconnect hose (17) .
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Remove 22 bolts (18) and the washers from aftercooler (3) . Remove gasket (19) from aftercooler (3) . Use a suitable nylon lifting strap and a hoist and remove aftercooler (3) and heater assembly (13) from the engine. The weight of the aftercooler and the heater assembly is 16 kg (35 lb) .
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Remove gasket (20) from the engine.Installation Procedure
Inspect the gaskets. If the gaskets are worn or damaged, use a new Caterpillar part for replacement.
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Install gasket (20) to the engine.
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Use a suitable nylon lifting strap and a hoist and install aftercooler (3) and heater assembly (13) to the engine. The weight of the aftercooler and the heater assembly is 16 kg (35 lb). Install gasket (19) to aftercooler (13) . Before installation, apply 4C-9505 Gasket Sealant to the bolts. Install 22 bolts (18) and the washers to aftercooler (3) .
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Connect cable assembly (12) to heater assembly (13) and install nut (11) . Tighten nut (11) to 7.8 1.0 N m (69 8.9 lb in). Connect ground strap (15) and install nut (14) to heater assembly (13) . Tighten nut (11) to 8 1.0 N m (69 9 lb in). Connect hose (17) and tighten retaining nut (16) .
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Connect dipstick guide tube (9) to bracket (10) and install nut (8) .