803508017 Mercury GASKET, Cylinder Head Cover

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact the skin. Be sure that the engine and components are cool enough to touch with your bare hand prior to performing any service work.
At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water or steam. Any contact can cause severe burns. Look at the sight gauge to check the coolant level. The coolant level should be in the green range. If necessary, remove the fill cap only after the engine has been stopped and the cap is cool enough to remove with your bare hand. Remove the cooling system fill cap slowly to relieve pressure. Cooling system condition contains alkali that can cause personal injury. Avoid contact with the skin and eyes and do not drink. Allow cooling system components to cool before draining.
Mark and identify all hose assemblies for installation purposes. Cap and plug all hose assemblies to avoid system contamination.1. Turn the fuel supply valve, located on the fuel tank, to the "Off" position. 2. Position a suitable container under drain plug (2) to contain the coolant for storage or disposal. Loosen drain plug (2) on radiator elbow (1). Repeat procedure on remaining drain plug. The capacity of the cooling system is 300 L (79 U.S. gal). 3. Position a suitable container under pipe plug (5) to contain the engine oil for storage or disposal. Remove pipe plug (5) from adapter plug (4). Loosen oil drain plug (3) and drain the engine oil. The oil capacity of the engine is 125 L (33 U.S. gal). 4. Position a suitable container under bolt (6) to contain the engine oil for storage or disposal. Remove bolt (6) and the washer from oil pan rear section (7). 5. Remove two socket head bolts (8) from each implement pump (9). Remove bolt (10) and the washer that holds grate (11). 6. Put Tool (A) in position on implement pumps (9) and grate (11), as shown. Mark and identify all cable assemblies and wiring harness for installation purposes.7. Disconnect two positive battery cable assemblies (13) and two negative battery cable assemblies (12) from starting motors (14) and (15). 8. Disconnect hose assemblies (16) and (17) at the connections. 9. Remove four bolts (18), the washers, and the gasket from elbow (19). Repeat process for the remaining elbow. 10. Remove three hose assemblies (20), (21), and (22) from air compressor (23). 11. Disconnect hose assembly (24) from auxiliary fresh water pump (25). 12. Remove four bolts (27) and the clip from auxiliary fresh water pump (25). Disconnect hose assembly (26). Remove elbow (28) and the O-ring seal from auxiliary fresh water pump (25). 13. Remove bolt (29) and the washer. Set hose assembly (30) out of the way. 14. Disconnect two wiring harnesses (31) and (32) at the electrical connections. 15. Disconnect wiring harness (33) and (34) at the electrical connections. 16. Remove four bolts (35) and the washers from clips (36). 17. Remove bolt (37) and the washer from clip (38). Disconnect wiring harness (33) at the electrical connections. 18. Disconnect hose assembly (40) from elbow (39). 19. Loosen two hose clamps (41) and (42) on hoses (43) and (44). Disconnect hoses (43) and (44). 20. Remove 11 tie straps (46) that hold wiring harness (45). Remove wiring harness (45) from engine (47). 21. Disconnect wiring harness (48) from the aftercooler temperature sensor at the electrical connection. Remove two bolts (50) and the washers from tube (51). Remove tube (51) and the O-ring seal from aftercooler (49). 22. Remove bolt (52) that holds bracket (53) to engine (47). 23. Disconnect tube assembly (54) from oil pan front section (55). 24. Remove two bolts (56) and the washers from oil level gauge (dip stick) (57). Remove oil level gauge (dip stick) (57) and the shaft gasket from oil pan front section (55). 25. Disconnect wiring harness (58) from the liquid level switch assembly at the electrical connection. 26. Remove eight bolts (59) and the washers from oil pan front section (55). 27. Position a suitable lifting device, (not shown), under oil pan (55). Remove 19 bolts (60) and the washers from oil pan (55). Remove oil pan front section (55) and the integral seal from engine (47). The weight of oil pan front section (55) is 62 Kg (137 lb). 28. Fasten a suitable lifting device to the lifting eyes on engine (47), as shown. Secure the lifting device to a hoist. 29. Remove four bolts (61) and the washers from engine support (62). 30. Remove 16 bolts (63) and the washers that hold engine (47) to the pump drive.31. Check to make sure all items have been disconnected from engine (47). Carefully remove engine (47) from the pump drive and the frame. The weight of engine (47) is 6107 Kg (13452 lb). The following steps are for the installation of the engine. Inspect all O-ring seals for wear or damage and replace as necessary. 32. Fasten a suitable lifting device to the lifting eyes on engine (47), as shown. Secure the lifting device to a hoist. Put engine (47) in position on the pump drive and the frame. The weight of engine (47) is 6107 Kg (13452 lb). 33. Install 16 bolts (63) and the washers that hold engine (47) to the pump drive. 34. Install four bolts (61) and the washers to engine support (62).35. Apply 4C-9613 Silicon Sealant to both sides of the joints on the oil pan gasket and at the point on the pan rail where the oil pan sections meet. 36. Position a suitable lifting device, (not shown), under oil pan front section (55). Put oil pan front section (55) and the integral seal in position on engine (47). Install 19 bolts (60) and the washers in oil pan front section (55). The weight of oil pan front section (55) is 62 Kg (137 lb).