804899002 Mercury GROMMET

Start By:a. remove air cleaner housingb. remove muffler1. Drain the cooling system and the hydraulic system. 2. Put identification marks on and disconnect five lines (1).3. Remove four bolts (2) and disconnect the large tube from the pump.4. Remove five bolts (3) and remove the shroud assembly. Cap all lines and cover all connections to keep debris out of the hydraulic system. 5. Remove four bolts (4) and rubber shield (5). 6. Remove two clips (6) and disconnect the hoses from the water pump and the cylinder head. Identify with marks for location.7. Disconnect water temperature sending unit (7) from the cylinder head. Disconnect all the clips from the engine. 8. Put identification marks on two wires (8) and disconnect.9. Disconnect fitting (9). 10. Disconnect two clips (10) from the cylinder block.11. Disconnect wire (11) from the oil temperature sending unit. 12. Remove four bolts (12) and remove the shroud. 13. Put identification marks on and disconnect two wires (13).14. Remove two bolts (14) and remove the muffler support bracket.15. Disconnect two fuel lines (15).16. Put identification marks on and disconnect two wires (16) from the starter.17. Remove all the plastic fasteners that hold the wiring harness to the fuel injection lines. 18. Remove the bolt and disconnect clip (17) from the oil pan.19. Put identification mark on wire (18) and disconnect from the alternator. 20. Remove pin (19) and disconnect the linkage for the governor and fuel injection pump. 21. Put identification mark on wire (20) and disconnect from the starter.22. Loosen nut (21) and disconnect the governor linkage from the mounting bracket. 23. Disconnect two hydraulic lines (22) from hydraulic oil cooler (23). 24. Attach tooling (A) to engine package. 25. Remove two front mounting bolts (24) from each side of the engine. 26. Remove two rear mounting bolts (25) and one cap (26) from each side of the engine.27. Remove engine, radiator and pump drive as a unit. The weight of the unit is 2400 kg (5280 lb.) Adjust tooling (A) as needed to level unit.Install Engine, Radiator And Pump Drive
1. Fasten a hoist and tooling (A) to the engine. Put the unit in position on the machine. Adjust tooling (A) to level unit.2. Install one cap (26) and two bolts (25) on each side of the engine rear support. 3. Install two bolts (24) on each side of the engine front support. 4. Connect two hydraulic lines (22) to hydraulic oil cooler (23). 5. Put the governor linkage cable in position on the bracket and tighten nut (21).6. Attach wire (20) to the starter. 7. Attach the governor cable to the governor and fuel injection pump with pin (19). Install the cotter pin. 8. Attach wire (18) to the alternator.9. Attach clip (17) to the oil pan. 10. Attach two wires (16) to the starter.11. Attach two fuel lines (15).12. Put the muffler support bracket in position and install two bolts (14).13. Connect two wires (13) to the oil pressure sending unit. 14. Put the shroud in position and install four bolts (12). 15. Attach two clips (10) to the block.16. Attach wire (11) to the oil temperature sending unit. 17. Connect fitting (9).18. Connect two wires (8). 19. Put the two water hoses in position and install two clips (6). Connect the hoses to the water pump and the cylinder head.20. Connect water temperature sending unit (7) in the cylinder head. Replace the clips to the engine. 21. Put shield (5) in position on the radiator and install four bolts (4). 22. Put the shroud in position and install five bolts (3).23. Connect five hydraulic lines (1).24. Put the tube assembly in position on the pump and install four bolts (2).25. Fill the cooling system and hydraulic system. See the Maintenance Manual.End By:a. install mufflerb. install air cleaner housing