835427A04 Mercury GASKET SET, Powerhead

At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. Remove the fill cap on the hydraulic oil tank only when the engine is stopped, and the fill cap is cool enough to touch with your bare hand.
1. Release the pressure in the hydraulic system by slowly loosening the fill cap located on top of the hydraulic oil tank.2. Drain the hydraulic oil from the fuel/hydraulic oil tank. The capacity of the hydraulic oil portion of the tank is 55 liters (14.5 U.S. gal).
At operating temperature, the engine cooling system is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap and radiator are cool enough to touch with the bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
3. Release the pressure in the cooling system by slowly loosening the fill cap on the radiator.4. Drain the coolant from the cooling system into a suitable container. The capacity of the cooling system is 25.7 liters (6.25 U.S. gal). 5. Position wooden blocks under the machine as shown. 6. Remove the two nuts and bolts that fasten clamp (3) to brace assembly (1).7. Remove the bolt and clamp that holds hose assembly (4) to the brace assembly.8. Remove the nut and bolt that fastens service meter (5) to the brace assembly.9. Mark or identify the cable assemblies for installation purposes. Disconnect cable assemblies (2) from the quick start post. 10. Remove the bolt and clamp that holds hose assembly (6) to the brace assembly.11. Mark or identify the cable assemblies for installation purposes. Disconnect cable assemblies (7) and (8) from the disconnect switch. 12. Attach lifting straps and a hoist to brace assembly (1) as shown. Remove seven remaining nuts and bolts (9), and remove the brace assembly from the machine. The weight of the brace assembly is 27 kg (60 lb). 13. Disconnect hose assemblies (10) and (11). Cap and plug immediately.
View From Under Machine14. Disconnect hose assemblies (12). Cap and plug immediately. 15. Disconnect hose assemblies (13) and (14). Cap and plug immediately.16. Remove the nut and bolt that fastens clip (15) and the hose assembly to the other clip. 17. Disconnect hose assemblies (16). Cap and plug immediately.18. Remove valve (18) from the propel pump. Disconnect hose assembly (17). Cap and plug immediately. Install valve (18) in the propel pump. 19. Disconnect hose assemblies (19), (20), (21) and (22). Cap and plug immediately. 20. Disconnect hose assemblies (23). Cap and plug immediately. 21. Disconnect hose assemblies (24) and (26). Cap and plug immediately.22. Remove the bolt that holds clip (25), and move the hose assembly out of the way. 23. Remove bolt (28) and hose clamps (27), and move the two hose assemblies out of the way. Remove bolts (29) and hose clamps (30), and move the three hose assemblies out of the way. 24. Remove the nut and bolt that fastens clip (31) and the hose assembly to the frame.25. Remove bolt (32) and the hose clamp that hold the fuel lines and hose assemblies in place. 26. Close fuel shut-off valves (33). Disconnect fuel lines (34) and (35) from the shut-off valves. Cap and plug immediately. 27. Remove the remaining bolt and clamp holding fuel line (34) to the side of the engine compartment.28. Disconnect hose assembly (36). Cap and plug immediately.
Rear View Of Engine29. Remove nuts (37) that fasten bracket (38) to the side of the engine. Move bracket (38) and the hose assemblies out of the way.
Front View Of Engine30. Remove the bolt holding clamp (39) and clip (40). Move the three hose assemblies out of the way. 31. Disconnect hose assembly (36) from the steering pump, and remove the hose assembly from the engine. Cap and plug immediately. 32. Disconnect hose assembly (41). Cap and plug immediately. 33. Remove the nut, and disconnect governor control cable (42) from the governor control. Loosen jamnut (43), and remove governor control cable (42) from the bracket.
View From Under Machine34. Mark or identify the cable assemblies for installation purposes. Disconnect cable assembly (44) from the starter. Remove the bolt that fastens clip (45) and the cable assembly to the engine. Disconnect cable assembly (ground) (46) from the frame. 35. Remove the bolt and three screws (47), and separate electrical connector (48). Disconnect electrical connector (49). 36. Remove the bolt that fastens ground wire (50) to the frame. Disconnect electrical connectors (51). Remove all the cable ties that hold the wiring harnesses to the frame. 37. Put identification marks on wires (52) for installation purposes. Disconnect the wires from the fuel level sending switch. Remove cable ties (53) that fasten the wiring harness to the fuel/hydraulic oil tank and the frame. Move the wiring harness out of the way. 38. Put identification marks on the three wires connected to service meter (5). Disconnect the three wires from the service meter.39. Put identification marks on two wires (54) for installation purposes. Disconnect the two wires from the hydraulic oil temperature switch. 40. Remove the two bolts that fasten starter relay switch (55) to the frame. Remove all the cable ties that fasten the harness assembly to the frame. Move the wiring harness out of the way. 41. Remove four nuts and bolts (56) that hold the engine to the frame of the machine.42. Attach Tooling (A) and a hoist to engine (56) as shown. Make sure all the necessary hose assemblies and electrical wires have been disconnected. Carefully remove the engine, radiator and pumps as a unit from the machine. The weight of the engine, radiator and pump as a unit is 726 kg (1600 lb). After the engine has been installed, fill the cooling system with coolant to the correct level. Fill the hydraulic oil tank to the correct level. See the Operation & Maintenance Manual for the correct