803753002 Mercury PLATE, Water Pump Guide

At operating temperature, the engine coolant 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 is cool enough to touch with your 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.
2. Remove radiator fill cap slowly, to release the pressure in the cooling system. Drain the coolant from the radiator in a suitable container for storage or disposal. The capacity of the cooling system is 183 liters (47.6 U.S. gal).
Hot engine oil and components can cause personal injury. Do not allow hot engine 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.
3. Remove six bolts (2) that hold bonnet (3) to the transmission oil cooler. Remove six bolts (1) that hold bonnet (3) to the engine. A small amount of oil and coolant will drain out of the transmission oil cooler and the engine oil cooler at this time. Position a suitable container under the coolers to collect the fluids. 4. Remove bonnet (3) with O-ring seal (4) and two gaskets (not shown) from the engine oil cooler and the transmission oil cooler. 5. Mark and identify two bolts (6) for installation purposes. Remove two bolts (6) that hold engine oil cooler (5) to engine oil cooler bypass body.6. Mark and identify two bolts (8) for installation purposes. Remove two bolts (8) that hold engine oil cooler (5) to engine oil cooler outlet body.7. Remove engine oil cooler (5) and adapter from cooler inlet bonnet (7). Remove seals (not shown) from engine oil cooler bypass body and outlet body. 8. Remove adapter (10) from engine oil cooler (5).9. Remove two O-ring seals (9) from adapter (10). The following steps are for the installation of the engine oil cooler. 10. Carefully clean the tube bundles in engine oil cooler (5) with a 3.2 mm (.125 in) diameter rod. 11. Lubricate the bore and new O-ring seals (9) lightly with glycerin. Install two O-ring seals (9) on adapter (10). Install adapter (10) in engine oil cooler (5). 12. Install new seals in engine oil cooler bypass and outlet bodies. Put engine oil cooler (5) in position in cooler inlet bonnet (7).13. Install two bolts (8) that hold engine oil cooler (5) to engine oil cooler outlet body.14. Install two bolts (6) that hold engine oil cooler bypass body. 15. Lubricate bore and new O-ring seal (4) lightly with glycerin. Install O-ring seal (4) on bonnet (3). Install new gaskets on bonnet (3) at the transmission oil cooler and engine block. 16. Put bonnet (3) in position in the engine oil cooler and on the transmission oil cooler. Install six bolts (1) that hold bonnet (3) to the engine.17. Install the remaining six bolts (2) that hold bonnet (3) to the transmission oil cooler.18. Tighten bolts (1) to a torque of 47 9 N m (35 7 lb ft).19. Tighten bolts (2) to a torque of 105 20 N m (77 15 lb ft).20. Install rear crankcase guard. Refer to the Operation & Maintenance Manual for all fluid capacities and the proper filling procedures.