803750 2 Mercury HOUSING, Water Pump - Upper

Table 1
Required Tools
Tool Part Number Part Description Qty
A 207-5034(1) Stud Tensioner Tool Gp 1
301-5215(2) Stud Tensioner Tool Gp 1
B 8T-3035 Hydraulic Line 1
8T-0820 Hydraulic Pressure Gauge 1
350-7768(3) Electric Hydraulic Pump Gp (115v ) 1
350-7769(3) Electric Hydraulic Pump Gp (230v ) 1
9U-6600(3) Hand Hydraulic Pump 1
C - Steel Beam
152 mm by 152 mm by 5 m (6 inch by 6 inch by 15 ft) 2
D 8T-0960 Handling Tool Gp 1
(1) Operating pressure is 65000 2400 kPa (9425 348 psi).
(2) Operating pressure is 111500 3950 kPa (16170 575 psi).
(3) There are three pumps that are listed in the tool chart. Only one pump is required for the procedure.Start By:
Remove the engine oil filler and the oil level gauge.
Remove the centrifugal oil filters.
Remove the crankcase explosion relief valves.
Remove the crankshaft rear gear.
Remove the crankshaft front gear.
Remove the pistons and connecting rods.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
There is no set procedure for removing the crankshaft. Each engine installation will require a specific procedure to be followed. To determine the best procedure for the removal of the crankshaft in your application, consult the Dealer Solutions Network.Note: There are no special tools for lifting and supporting the C280 Engine.Each engine has been designed so that the crankshaft can be removed without removing the front timing gear housing. Use the procedure that follows.
Failure to securely block or support the engine properly could allow engine movement that may result in injury or death. Always use blocks, jack stands, or engine support stands in order to support the engine prior to the removal of the crankshaft.
Illustration 1 g01316955
Remove engine mounting bolts (2) and bolts (1) from each side of the engine.
Remove the remaining crankcase access covers.
Remove the bolts that connect the engine oil pan to the cylinder block.
Use a suitable lifting device to raise the engine until there is enough room for the removal of the crankshaft. Raise the engine approximately 0.6 m (2.00 ft). The weight of the C280-12 Engine is approximately 26000 kg (57300 lb). The weight of the C280-16 Engine is approximately 30000 kg (66100 lb).
The engine oil pan will remain in the mounting base when the engine is raised. Remove the gasket from the engine oil pan.
Use suitable cribbing to support the engine. Tooling (C) may be used to support the engine.
Never support a marine engine on hard wood blocks or steel beams. Vessel movement could cause engine movement. This may result in personal injury or death. Engine blocking for marine applications should only be done while the vessel is in drydock.
Place Tooling (A) in position under the rear main bearing cap.
Put the sleeve in position over the nuts. Install the wrench into one of the holes in the nut.
Raise Tooling (A) until Tooling (A) is against the reaction sleeve.
Install the adapter nuts. Tighten the nuts by using a 1/2 inch ratchet. After the nuts are tight, the nuts should be loosened 1 1/2 turns.
Before you operate the pump, ensure that all connections are secure. Ensure that all hoses are in good condition. Oil escaping under high pressure can cause personal injury.
Note: The stud tensioner tool groups in Tooling (A) require different operating pressure.
Run the pump in Tooling (B) until the operating pressure is registered on the gauge. This will put tension on the studs so that the nuts can be loosened.
Use the dowel handle in order to loosen each nut for 1 1/2 turns (12 holes).
Slowly release the hydraulic pressure.
Repeat Step 7 through Step 13 for each main bearing cap.
Use Tooling (D) to support the rear main bearing cap. Remove the nuts and washers. Lower the rear main bearing cap. If necessary, tap the rear main bearing cap with a suitable hammer to loosen the rear main bearing cap. The weight of each main bearing cap is approximately 65 kg (145 lb). Note: Remove only the rear main bearing cap at this time.
Remove the lower half of the main bearing from the rear main bearing cap. Put an identification number on the lower half of the main bearing.
Illustration 2 g01315243
Remove rear thrust plate (3). Carefully pry the crankshaft so that rear thrust plate (3) can be rolled out of the cylinder block. Remove the thrust plates on the rear main bearing for rear driven equipment. Remove the thrust plates on the front main bearing for front driven equipment.