78203A 2 Mercury SPRING ASSEMBLY --NOT USED WITH POWER TRIM

Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 4
ZZ 6V-9507 Face Seal Plug 2
6V-9828 Cap As 2
6V-9830 Cap As 2
6V-9509 Face Seal Plug 2
6V-9510 Face Seal Plug 1
6V-9831 Cap As 1
6V-9511 Face Seal Plug 2
6V-9832 Cap As 2 Start By:
Remove the hood. Refer to Disassembly and Assembly, "Hood - Remove".
Remove the air cleaner. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. 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 cooling system pressure cap is cool enough to touch with your bare hand.Remove the cooling system pressure cap slowly to relieve pressure.Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.
At operating temperature, the hydraulic tank is hot and under pressure.Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.
Personal injury can result from contact with refrigerant.Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area.Personal injury or death can result from inhaling refrigerant through a lit cigarette.Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death.Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.Dispose of all fluids according to local regulations and mandates.
Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.Note: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.
Drain the coolant from the cooling system into a suitable container for storage or disposal. The capacity of the cooling system is approximately 42 L (11.1 US gal). Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".
Drain the hydraulic tank into a suitable container for storage or disposal. The capacity of the hydraulic tank is approximately 70 L (18.5 US gal). Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change".
Recover the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the tools.
Illustration 1 g00986846
Disconnect hose assemblies (1) and (2).
Illustration 2 g00986847
Disconnect hose assemblies (3) and (4). Remove bolts (5) and the clamps. Position hose assemblies (1), (2), (3), and (4) out of the way.
Illustration 3 g00986849
Loosen hose clamps (6) and (7). Disconnect tube assembly (8) and hose (9).