804665A05 Mercury DECAL, EPA Label Information (2005)

1. Remove the bolts holding screen assembly (2) and open the screen assembly.
Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping Freon-12 (C C12 F2 Dichloro Difluoro Methane) can cause freezing of human flesh. Do not smoke while working on air conditioning systems. Inhaling Freon-12 through any smoking material, although not toxic or flammable, can generate phosgene gas and cause violent illness. Also, heat must never be applied to a charged system. See Air Conditioning And Heating Service Manual, Form No. SENR7454, for more information on removal and installation of lines and refrigerant from the system.
2. Release the pressure in the air conditioning system. See Purging the System in Air Conditioning And Heating Service Manual, Form No. SENR7454.3. Disconnect hose assemblies (1) and (4) from air conditioning condensor (3). Plug all the openings to prevent any moisture from entering the system. 4. Fasten a hoist to radiator core (5).5. Remove bolts (6) and cap (7) from each side of the radiator core. 6. Remove three bolts (8) and washers. Remove shaft and mount assembly (9) from each side of the radiator core. 7. Remove two bolts (11) and cap (10) from the lower mounts on each side of the radiator core.8. Remove radiator core (5). The radiator core weighs 600 kg (1320 lb.). 9. Remove mount assembly (12) from shaft (13). If necessary remove the lower mount assemblies from the radiator core. The following steps are for the installation of the radiator core.10. Assemble mount assembly (12) on shaft (13) and on the radiator core. Install mount assembly (12) onto shaft (13) until the mount face is against the mating face on shaft (13). Then stake the shaft to prevent the mount assembly from moving.11. Use a hoist and install the radiator core into the lower supports on the radiator guard.12. Install caps (10) and bolts (11). Do not tighten bolts (11) at this time.13. Pivot the radiator core into position for the installation of the top mounts.14. Install shaft and mount assemblies (9) on each side of the radiator guard and install three bolts (8) and washers.15. Install caps (7) and bolts (6). Tighten bolts (6) and bolts (11) for the lower mounts at this time.16. Remove the hoist from radiator core (5).17. Connect hose assemblies (1) and (4) to the air conditioning condensor (3).18. See Air Conditioning And Heating Service Manual, Form No. SENR7454, for the correct procedure for evacuating and charging the system.19. Close screen assembly (2) and install the bolts to hold it in position.End By: a. tilt radiator guard backwardDisassemble Radiator Core (D10N)
Start By: a. remove radiator core1. Remove the fan guard. 2. Remove four shields (1).3. Remove plate assemblies (2). 4. Install two 1/2" - 13 NC forged eyebolts (3) into radiator top tank (4). Fasten chains and a hoist to the forged eyebolts. The weight of the radiator tank is 50 kg (110 lb.).5. Remove the bolts that hold the radiator top tank to the channel assemblies.6. Remove the nuts and washers from the studs on the radiator top tank. The studs fit into slots in the channel assemblies. 7. Carefully lift the radiator top tank off the core assemblies. 8. At the front of the radiator, remove the bolts that hold the core assemblies to plate assembly (5).9. At each side of the radiator, remove the bolts that hold the outer core assemblies to the bracket assemblies.10. At the front of the radiator, remove seven strap assemblies.11. Remove the core assemblies from the radiator bottom tank.12. Remove the seals from the radiator top tank and radiator bottom tank.13. Inspect and replace damaged parts as necessary.Assemble Radiator Core
Seals (1) and (2) are different. The top seals have a longer tab spacing than the bottom seals. Be sure the tabs engage with the holes in the tanks.
1. Apply liquid soap to the sealing areas of seals (1), and install them in the radiator top tank. 2. Apply liquid soap to the sealing areas of seals (2), and install them in the radiator bottom tank. 3. Install core assemblies (3) into the seals in the radiator bottom tank. Install the core assemblies with the bevel edges together.4. Install the bolts and washers that hold the core assemblies to plate assembly (4), but do not tighten them at this time. 5. Install the bolts washers that hold the outer core assemblies to the brackets, but do not tighten the bolts at this time.6. Install the bolts and washers that hold the core assemblies to strap assemblies (5) and (6). Do not tighten the bolts at this time. 7. Carefully lower the radiator top tank into position on the core assemblies.8. Install the top tank to the core assemblies and the channel assemblies. Install the bolts, washers and nuts, but do not tighten them at this time.9. Adjust the air gap between the core assemblies at the front of the radiator to 5 to 8 mm (.197 to .315 in.).10. Tighten the bolts as the adjustments for each set of core assemblies is made.11. After the air gap for all the core assemblies has been established. Tighten the remaining bolts.12. Complete the assembly of the radiator.End By: a. install radiator core