803684 Mercury STUD

At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Drain the coolant only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to avoid personal injury.
1. Drain the coolant from the cooling system. 2. Attach a hoist to guard rail (1). Remove the bolts and guard rail (1). The weight of the guard rail is approximately 27 kg (60 lb).3. Remove the bolts and guard rail (2).4. Attach a hoist to guard rail (6). Remove the bolts and guard rail (6). The weight of the guard rail is approximately 48 kg (106 lb).5. Attach a hoist to step assembly (5).6. Remove the bolts that hold the step assembly in place. Remove the step assembly. The weight of the step assembly is approximately 87 kg (192 lb).7. Attach tooling (A) and a hoist to upper grill (4). Remove the mounting bolts and grill (4). The weight of the grill is 39 kg (86 lb).8. Attach tooling (A) and a hoist to lower grill (4). Remove the mounting bolts and grill (4). The weight of the grill is 39 kg (86 lb).9. Attach a hoist to the front hood assembly. Remove the bolts and the front hood assembly. The weight of the front hood assembly is approximately 92 kg (200 lb).10. Attach tooling (A) and a hoist to radiator cowl (3). 11. Remove eight bolts and washers (7). Remove radiator cowl (3). The weight of the cowl is 186 kg (410 lb). 12. Disconnect the hose assembly from tube assembly (8). Remove the O-ring seal.13. Disconnect and remove tube assembly (8) and the clips. Remove the O-ring seals.14. Remove the bolts that hold four elbows (9) to the radiator. Remove the gaskets. 15. Remove the bolts that hold two elbows (10) to the radiator. Remove the gaskets. 16. Remove the bolts that hold fan guard (11) to the radiator. Move the fan guard away from the radiator. 17. Remove two straps (12) that hold the bottom of the radiator to the frame.
Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping Freon-12 (C C12 F2 Dichloro Difluoro Methane) can cause freezing of human flesh.Do not smoke while working on air conditioning systems. Inhaling Freon-12 through any smoking material, although not toxic or flammable, can generate phosgene gas and cause violent illness. Also, heat must never be applied to a charged system. See Air Conditioning And Heating Service Manual, Form No. SENR3334, for more information on removal and installation of lines and refrigerant from the system.
18. Release the refrigerant from the air conditioning system. See the topic, Purging The System in Air Conditioning And Heating Service Manual, Form No. SENR3334.19. Disconnect hose assemblies (13) and (14) from air conditioning condensor (15). Put plugs or caps on all of the openings.20. Remove the bolts that hold the clips and hose assemblies (13) and (14) to the radiator. Move the hose assemblies away from the radiator.21. Fasten a hoist and tooling (A) to radiator (16).
Check to be sure all lines, hoses and wires are disconnected and out of the way before removing the radiator.
22. Remove two bolts (17) from each side of the radiator, and remove the radiator from the machine. The weight of the radiator is approximately 1050 kg (2310 lb) The following steps are for installation of the radiator.23. Fasten a hoist to radiator (16). Put the radiator in place on the machine. Install two bolts (17) to each side of the radiator.24. Connect hose assemblies (13) and (14) to air conditioning condensor (15).25. Install the bolts that hold the clips and hose assemblies (13) and (14) to the radiator.26. Install two straps (12) that hold the bottom of the radiator to the frame.27. Install the bolts that hold fan guard (11) to the radiator.28. Install the gaskets. Install the bolts that hold two elbows (10) to the radiator.29. Install the O-ring seals. Install tube assembly (8) and the clips. Connect the hose assembly.30. Install the gaskets. Install the bolts that hold four elbows (9) to the radiator.31. Attach tooling (A) and a hoist to radiator cowl (3).32. Install radiator cowl (3). Install eight bolts and washers (7).33. Attach tooling (A) and a hoist to lower grill (4). Install the mounting bolts and grill (4).34. Attach tooling (A) and a hoist to upper grill (4). Install the mounting bolts and grill (4).35. Attach a hoist to step assembly (5).36. Install the step assembly. Install the bolts that hold the step assembly in place.37. Fasten a hoist to guard rail (6). Install guard rail (6).38. Fasten a hoist to guard rail (1). Install guard rail (1).39. Install guard rail (2).40. Fill the cooling system with coolant to the correct level. See the Operation And Maintenance Manual.
Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping Freon-12 (C C12F2 Dichloro Difluoro Methane) can cause freezing of human flesh.Do not smoke while working on air conditioning systems. Inhaling Freon-12 through any smoking material, although not toxic or flammable, can generate phosgene gas and cause violent illness. Also, heat must never be applied to a charged system. See Air Conditioning And Heating Service Manual, Form No. SENR3334, for more information on removal and installation of lines and refrigerant from the system.
41. Evacuate and charge the air conditioning system. See procedures for evacuating and charging in the Air Conditioning And Heating Service Manual, Form No. SENR3334.42. Use a hoist to install the front hood assembly. The weight of the front hood assembly is approximately 92 kg (200 lb).