853830005 Mercury PLUNGER, Complete

2. Remove four bolts (1), washers and brace (2). 3. Remove six nuts (3) and lower half of fan guard (4). 4. Disconnect wiring harness (5) and tube (6) from the engine. 5. Remove bolt (7) and move hose (8) away from the engine. 6. Loosen hose clamp (9) and remove two bolts (10). Remove lower radiator elbow (11). 7. Remove bolt (12) and cab tilt cylinder (13). 8. Disconnect wiring harnesses (14) going to the control panel in the cab. 9. Remove two bolts (15) washer and clip. 10. Remove two bolts (16) and lower the control panel out of the way. 11. Disconnect pressure line (17) from the bottom of the hydraulic pump. 12. Remove two hose clamps (18) and slide hose (19) off of the hydraulic pump. 13. Disconnect three hose assemblies (20) from pilot pump (21). 14. Remove tube (22). 15. Loosen hose clamps (23) and disconnect fuel lines (24). Put plugs in the fuel lines to keep dirt out. 16. Remove pin (25) and disconnect governor linkage (26). Move the linkage out of the way. 17. Disconnect two lines (27) going to the compressor. Remove bolt (27), clip and move lines away from the engine. 18. Put identification on cables (29) and disconnect them from the starter. 19. Remove five bolts (30) and clips from wiring harness (31).20. Disconnect wires from forward/reverse switch (32).21. Disconnect three wires (not shown) on the bottom of the hydrostatic power control unit and move wiring harness (31) out of the way. 21. Remove the bolt from clamp (33) and move oil cooler line (34) away from the engine. 22. Fasten Tool (A) and a hoist to the engine as shown. 23. Remove bolts (35) that hold the flywheel housing to the hydrostatic power control unit. Move bracket (36) for the governor linkage out of the way. 24. Remove bolts (37) from the engine front supports.
Be sure all hose assemblies, linkage and electrical connections have been disconnected from the engine prior to removal.
25. Slide the engine away from the hydrostatic power control unit to disengage the drive coupling. Carefully remove the engine from the machine. The weight of the engine is approximately 1066 kg (2350 lb). The following steps are for the installation of the engine.26. Be sure the O-ring seal on the drive coupling is in position and put clean grease on the O-ring seal. 27. Fasten Tool (A) and a hoist to the engine. Carefully slide the engine into position on the hydrostatic power control unit. Put bracket (36) for the governor linkage in position and install bolts (35) that hold the engine and hydrostatic power control unit together. 28. Be sure top rubber mounts are in position on both sides of the frame and lower the front of the engine on to the mounts. Put the sleeves and lower rubber mounts in position and install bolts (37), washers and nut. Tighten the bolts to a torque of 570 80 N m (420 60 lb ft). 29. Install clamp (33) that holds oil cooler line (34). 30. Connect three wires (not shown) on the bottom of the hydrostatic power control unit going to wiring harness (31).31. Connect wires to forward/reverse switch (32).32. Install five bolts (30) and clips to hold wiring harness (31). 33. Connect cables (29) to their original locations on the starter. 34. Connect two lines (27) going to the compressor. Install bolt (27), clip to the engine. 35. Position governor linkage (26) and install pin (25). 36. Connect fuel lines (24) and tighten clamps (23). 37. Connect tube (22). 38. Connect three hose assemblies (20) to pilot pump (21). 39. Position hose (19) on the hydraulic pump and install clamps (18). 40. Connect pressure line (17) to the bottom of the hydraulic pump. 41. Position the control panel and install bolts (16) that hold it. 42. Install two bolts (15) washer and clip. 43. Connect wiring harnesses (14) going to the control panel in the cab. 44. Position cab tilt cylinder (13) and install bolt (12). 45. Position lower radiator elbow (11) and install hose clamp (9) and two bolts (10). 46. Position hose (8) on engine and install bolt (7). 47. Connect wiring harness (5) and tube (6) to the engine. 48. Position the lower half of fan guard (4) and install six nuts (3) that hold it. 49. Position brace (2) and install four bolts and washers (1).50. Fill the cooling system to the correct level.51. Fill the hydraulic tank to the correct level.52. Check the oil level in the hydrostatic power control unit.53. Install the guards below the engine and the track motors.End By:a. *lower the cab (from 90 degree position)b. install fanc. install battery boxesd. install hood*This procedure is found in SENR5371 Machine Systems Disassembly and Assembly Module.