813644002 Mercury GROMMET

Start By: a. tilt radiator guard forwardb. remove floorplatec. remove bottom guardsd. remove drive shaft*e. remove auxiliary drive shaft**This procedure is in the Power Train Disassembly And Assembly section.
Make sure the pins are installed in the levers of the fire suppression agent cylinders so the fire suppression system will not be activated. Personal injury can be the result if the fire suppression system is activated when fire suppression nozzle (11) is disconnected.
Disconnect batteries before performance of any service work.
1. Drain the oil from the power train oil system. The capacity that can be drained is approximately 159 liter (42 U.S. gal.). 2. Remove seven bolts (3) and remove shield assembly (1). Remove four bolts (2) for shield assemblies (4) and (5). Remove shield assemblies (4) and (5) on the left side of the engine. 3. Loosen clamps (6) and (8). Remove tube assembly (7). 4. Fasten a nylon strap and a hoist to air cleaner housing (9). Remove four nuts and bolts (10). Remove the air cleaner housing and support.5. Remove the bolts holding fire suppression nozzle (11) and bracket to the aftercooler housing. Move fire suppression nozzle to the side.6. Disconnect governor control rod (12) from the governor control shaft. 7. Disconnect hydraulic oil lines (14) and (15) from hydraulic oil cooler (13). 8. Disconnect ether starting aid tube (16). 9. Put identification on the electric wires as to their location on the starting motor for correct installation. Disconnect wires (17), (18) and wiring harness (19) from the starting motor. 10. Disconnect elbow (19), pressure control valve (17), and hose assembly (18). Disconnect hose assemblies (20) and (21) from the cooler oil pump. 11. Disconnect governor control linkage (12) from lever (23) and remove linkage (12) from the machine.12. Turn the fuel supply to the engine off. Disconnect fuel lines (24) from the back of the firewall. Put caps and plugs in the openings to keep dirt and foreign material out of the fuel system.13. Remove plates (25), (26) and (27) from the machine. 14. Disconnect hose assembly (28) from the torque divider outlet relief valve. 15. Disconnect hose assemblies (29) and (30) from the torque divider. 16. Disconnect hose assemblies (35) from the elbow.17. Loosen hose clamp (32), remove two bolts (33) and remove elbow (34) from the engine.18. Disconnect heater hoses (31) from the valves. 19. Disconnect wire harness (38). Put identification on wires (37). Disconnect wires (37) from the water temperature sensor.20. Remove bolts (36) from the engine front support on both sides of the engine. 21. Remove two bolts (40) and cap (39) from the rear engine supports. 22. Remove bracket (41) from the right side frame rail.23. Remove one of the bolts from the right side rear engine support and install a longer bolt and a 6V2157 link bracket (part of tooling B). 24. Fasten tooling (A) to a hoist and to the lifting brackets on the engine. Use a nylon sling to fasten the 6V2157 link bracket to 5P9694 ratchet hoist (tooling B) as shown. Use tooling (B) to prevent the engine and torque divider from rotating during removal.25. Tilt and remove the engine and torque divider with tool (A). The engine and torque divider weigh approximately 3175 kg (7000 lb.).Install Engine And Torque Divider
1. Fasten a hoist to the engine with tool (A).2. Fasten tooling (B) to right side rear engine support and the hoist.3. Lift the engine and torque divider. Use tooling (B) to prevent the engine and torque converter from rotating on the engine lifting brackets.4. Tilt the engine and torque divider with tooling A and put it in position on the machine.5. Remove 6V2157 Link Bracket (part of tooling B) and install the bolt that was removed. Install bracket (41).6. Install caps (39) and bolts (40) on the rear engine supports.7. Install bolts (36) in the engine front supports. Tighten bolts (36) and (40) to a torque of 570 80 N m (420 60 lb.ft.).8. Connect wire harnesses (38). Connect two wires (37) to the water temperature sensor.9. Connect heater hoses (31) to the valves.10. Put elbow (34) in position and install two bolts (33). Tighten hose clamp (32). Connect hose assemblies (35) to the elbow.11. Connect hydraulic hose assemblies (29) and (30) to the torque divider.12. Connect hose assembly (28) to the torque divider outlet relief valve.13. Install plates (25), (26) and (27) in the firewall.14. Put governor control linkage (12) in position and connect it to lever (23).15. Connect fuel lines (24) and turn on the fuel supply to the engine. Remove (bleed) the air from the fuel system.16. Connect wire harness (22).17. Connect elbow (19), pressure control valve (17) and hose assembly (18) to the pump. Connect hose assemblies (20) and (21) to the cooling oil pump.18. Connect wiring harness (19), wires (17) and (18) to the starting motor.19. Connect ether starting tube (16).20. Connect hydraulic oil lines (14) and (15) to the hydraulic oil cooler (13).21. Connect governor control rod (12) to the governor control shaft.22. Install the fire suppression bracket to the aftercooler housing. Install fire suppression nozzle (11) on the bracket.23. Put air cleaner housing (9) and the support in position. Install four nuts and bolts (10).24. Before assembly coat both outside end surfaces of tube assembly (7) with Dow Corning Molykote Paste Lubricant #505. Install clamps (6) and (8). Tighten both clamps to a torque of 8 0.5 N m (70 4 lb.in.).25. Install shield assemblies (4), (5) and (1).26. Fill the power train with oil to the correct level. See the Maintenance Guide.End By: a. install auxiliary drive shaft*b. install drive shaft*c. install bottom guardsd. install floorplatee. tilt radiator guard backward