802739A06 Mercury DECAL SET

At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Drain the coolant 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 avoid personal injury.
1. Drain the coolant from the cooling system.2. Disconnect the water pump inlet from the radiator.
Typical Examples3. Remove the bolts that hold trunnion (2) to the frame of the vehicle. The weight of the engine trucks is approximately 7030 kg (15500 lb).4. Fasten a hoist to the engine and lift it enough to remove the weight from trunnion (2). Put blocks under the engine block to hold the front of the engine up, and remove the hoist.5. Remove three of bolts (1), and install three 1/2" - 13 NC guide bolts (3). Remove the remainder of bolts (1) from the trunnion. 6. Pull trunnion (2) away from the front drive housing enough to fasten a hoist as shown. Remove trunnion (2) from the engine. The weight of trunnion (2) is 54 kg (119 lb). 7. Remove the bolts to remove mount assembly (4) from trunnion (2) if necessary. The weight of mount assembly (4) is 20 kg (44 lb). The following steps are for installation of the trunnion.8. Put mount assembly (4) in position, and install the bolts to hold it to trunnion (2). Tighten the bolts to a torque of 190 30 N m (140 22 lb ft).9. Install three 1/2" - 13 NC guide bolts (3) in the front drive housing. Fasten a hoist to trunnion (2), and put it in position on the guide bolts. Remove the hoist, and install 27 of bolts (1) to hold trunnion (2) in position. Remove the guide bolts, and install the remainder of bolts (1). Tighten all of bolts (1) to a torque of 135 15 N m (100 11 lb ft).10. Fasten a hoist to the front of the engine, and lift it to remove the blocks under it. Lower the engine until trunnion (2) is against the frame of the vehicle. Remove the hoist, and install the bolts that hold the trunnion and engine in position. Tighten the bolts to a torque of 475 50 N m (350 37 lb ft).11. Connect the water pump inlet to the radiator, and fill the cooling system with coolant to the correct level. See the Operation & Maintenance manual for further information.End By:a. install crankshaft pulley and vibration damperb. install oil panRemove & Install Engine Front Support
Start By:a. remove radiator 1. Remove the nuts and bolts (2) that hold the trunnion to the engine front support. Put two 50 ton screw jacks in position under the front drive housing at location (X). Raise the engine with the jacks until the trunnion is approximately 51 mm (2 in) above the engine front support.2. Fasten tooling (A) to tube assembly (4) at locations (Y).3. Fasten tooling (A) to engine front support (3) with two nylon straps.4. Remove bolts (1) that hold the engine front support ( to the frame.5. Use tooling (A) to lower engine front support (3) to the ground. The weight of the engine front support is 83 kg (183 lb). The following steps are for installation of the engine front support.6. Make sure the mating surfaces of the engine front support, trunnion and the frame are free of paint.7. Fasten tooling (A) to engine front support (3). Use tooling (A) to put the engine front support in position in the frame.8. Install bolts (1) that hold the engine front support to the frame. Tighten the bolts to a torque of 1800 200 N m (1325 150 lb ft).9. Remove tooling (A) from the engine front support and tube assembly (4).10. Use the two 50 ton screw jacks to lower the engine into position on the engine front support.11. Install bolts (2). Tighten the bolts to a torque of 475 50 N m (350 37 lb ft).End By:a. install radiator