803751002 Mercury PUMP, Liner Housing

2. Open engine access door (1) on the right side of the machine. 3. Remove engine side panel (2). Side panel is fastened to hood group and body with four bolts and washers (not shown). 4. Remove four bolts (4) and the washers that fasten air pipe (5) to air cleaner assembly (3). Remove air pipe (5) and gasket (6) from air cleaner assembly and turbocharger assembly. 5. Remove two oil tube assemblies (10) and coolant tube assembly (9) from turbocharger assembly (8). Disconnect coolant tube assembly (7) from rear of turbocharger assembly (8). It is not necessary to remove coolant tube assembly (7). The oil tube assemblies are sealed with O-rings and the coolant tube assemblies are sealed with gaskets at the turbocharger. Replace with new O-rings and gaskets at assembly. 6. Remove four bolts (12) and the washers that fasten tube assembly (13) to aftercooler assembly (11). Remove tube assembly (13) from turbocharger assembly (8). 7. Support turbocharger assembly (8) with nylon strap and hoist as shown. Remove four high temperature bolts and locknuts (14) that secure turbocharger (8) to the exhaust manifold. Remove turbocharger assembly (8) and the gasket (not shown) with nylon strap and hoist. The weight of the turbocharger is 32 kg (70 lb). 8. Remove exhaust coupling (17) from support (15). Remove seal ring (16) from each end of exhaust coupling. 9. Remove coupler (18) and elbow (19) from turbocharger assembly (8). Remove four O-ring seals (21) and four O-ring seals (20) from coupler and elbow. The following steps are for the installation of the turbocharger group. 10. Install four new O-ring seals (20) on elbow (19). Lubricate bore of turbocharger (8) and O-rings lightly with engine oil. Install elbow (19) as shown.11. Install four new O-ring seals (21) on coupler (18). Lubricate bore of turbocharger and O-ring lightly with engine oil. Install coupler (18) as shown. 12. Install a new seal ring (16) on each end of exhaust coupling (17). Apply a light coating of 5P3931 Anti-Seize compound to seal rings and install exhaust coupling (17) in the bore of support (15).13. Install a new gasket on exhaust manifold. 14. Install turbocharger assembly (8) on exhaust manifold using hoist and nylon strap.15. Apply 5P3931 Anti-Seize Compound on the threads of high temperature bolts and locknuts (14). Install four high temperature bolts and locknuts (14). Tighten to a torque of 55 5 N m (41 4 lb ft). 16. Install a new O-ring in the groove of tube assembly (13) at aftercooler. Lubricate bore of tube assembly (13) and the O-rings of the coupler with a light coat of engine oil. Install tube assembly (13). Fasten tube assembly (13) to aftercooler (11) with four bolts (12) and the washers. 17. Install a new gasket and connect coolant tube assembly (7) to rear of turbocharger (8). Install a new gasket and coolant tube assembly (9). Install new O-ring seals on oil tube assemblies (10). Install two oil tube assemblies (10). 18. Lubricate bore of air pipe (5) and the O-ring seals of the turbocharger elbow with a light coat of engine oil. Install air pipe in turbocharger elbow. Install new gasket (6) at air cleaner (3) and fasten air pipe (5) with four bolts (4) and the washers. 19. Install engine side panel (2).20. Fill radiator with proper quantity of coolant. Refer to the Operation & Maintenance Manual for all fluid capacities and proper filling procedures.