Specifications

CE78

Power Package Recommissioning

IMPORTANT: This service should be performed by an Authorized MerCruiser Dealer.

WARNING

To prevent possible injury or damage to equipment, do not install battery until all maintenance has

been performed on engine.

1 Reinstall seawater pump components and pump as follows:

NOTE: Use new gasket and O-ring. Install in correct position.

A Place impeller in pump housing.

B Install new O-ring in groove on housing.

C Install pump plate, with new gasket in position as shown.

D Engage pump shaft key in impeller keyway and install seawater pump cover. Align matching marks made prior

to disassembly.

E Install the three seawater pump cover mounting screws. Tighten securely.

F Install pump on engine using mounting bolt and tensioning bolt with hardware. Tension drive belt. Tighten

fasteners securely.

2 Check that all cooling system hoses are in good condition, connected properly, and hose clamps are tight.

3 Replace fuel filter.

4 Bleed fuel system (see “MAINTENANCE - FUEL SYSTEM”).

5 Fill up with fresh diesel fuel. Old fuel should not be used. Check fuel lines and connections for leaks and gener-

al condition.

CAUTION

When installing battery, be sure to connect POSITIVE (+) battery cable to POSITIVE (+) battery terminal

FIRST, and NEGATIVE (–) battery cable to NEGATIVE (–) battery terminal LAST. It battery cables are re-

versed, or connection order is reversed, electrical system damage will result.

6 Install fully-charged battery. Clean battery cable clamps and terminals and reconnect cables (see CAUTION

listed above). Secure each cable clamp when connecting. Coat terminals with a battery terminal anti-corrosion

spray to help retard corrosion.

7 Perform all checks on OPERATION CHART in the STARTING PROCEDURE column.

IMPORTANT: Avoid starter motor overheating. DO NOT engage starter for more than 15 seconds; allow

at least one minute cool-down time before re-engaging starter for another 15 seconds.

8 Start engine and closely observe instrumentation to make sure that all systems are functioning correctly.

9 Carefully inspect engine for fuel, oil, fluid, water and exhaust leaks.

10Check steering system, shift and throttle control for proper operation.