2A-2 - INSTALLATION - ALPHA ONE DRIVES 90-823225--1 1096
Removal
IMPORTANT: Stern drive unit must be removed
prior to engine removal. Refer to Stern Drive Ser-
vice Manual.
Engine Removal
1. Disconnect battery cables from battery.
2. Remove instrument harness connector plug from
engine harness receptacle after loosening
clamp.
!
WARNING
Be careful when working on fuel system. Gaso-
line is extremely flammable and highly explosive
under certain conditions. Do not smoke or allow
spark or open flame in area. Wipe up any spilled
fuel immediately.
3. Disconnect and suitably plug fuel line to prevent
fuel in tank from leaking into bilge.
4. Disconnect throttle cable from carburetor and re-
tain locknuts and hardware.
5. Disconnect bullet connectors of trim sender wires
(coming from transom assembly) from engine
harness.
NOTE: After wires are disconnected be sure to loos-
en them from clamps or Sta-Straps retaining them to
engine or hoses.
6. Slide sleeves back on BLACK and WHITE/
GREEN (or gray) wires and disconnect engine
harness wires from shift cut-out switch harness.
7. Disconnect MerCathode wires from MerCathode
controller if so equipped.
8. Disconnect seawater inlet hose from gimbal
housing.
9. Disconnect exhaust elbow hoses (bellows).
10. Remove both shift cables from shift plate. Retain
locknuts and hardware.
11. Disconnect any grounding wires and accessories
that are connected to engine.
12. Disconnect (and suitably plug) fluid hoses from
power steering control valve on transom.
!
CAUTION
Center lifting eye (located on top of thermostat
housing) is used for engine alignment only. DO
NOT use to lift entire engine.
!
CAUTION
DO NOT allow lifting sling to hook or compress
engine components or damage will occur.
13. Support engine with suitable sling through lifting
eyes on engine and remove front and rear engine
mounting bolts. Retain hardware.
72579
72581
a
b
a
72977
b
a
a - Suitable Sling
b - Engine Lifting Eyes
14. Carefully remove engine. DO NOT hit power
steering control valve.
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