803740 1 Mariner GEAR, Pinion

Table 1
Required Tools
Tool Part Number Part Description Qty
A 8T-3029 Camshaft Support 1
1U-6311 Plate 1
B 1P-2382(1) Wrench Adapter 1
9U-5932(1) Torque Wrench Extension 1
C 6V-6080 Torque Multiplier Gp 1
5P-1748 Socket 1
(1) Only one tool is required. Be sure that the proper tool is used for your engine.Start By:
Remove the valve lifter groups.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g00575670
Illustration 2 g00643307
Remove the camshaft inspection covers from the side of the cylinder block. Note: The engine must be rotated to remove all of the bolts that hold camshaft segment (4) in position.
Use Tooling (B) to loosen bolts (1) on the outside of camshaft segment (4).
If necessary to remove camshaft journal (2), loosen bolts (3) on the outside diameter.
Rotate the engine until bolts (1) and bolts (3) that were toward the inside of the cylinder block are on the outside.
Loosen remaining bolts (1) and bolts (3).
Illustration 3 g00643310Note: The engine cannot be rotated after camshaft drive gear (5) is removed. Be sure that all of the necessary bolts have been loosened before the camshaft drive gear is removed.
Remove camshaft drive gear (5), if camshaft drive shaft assembly (6) will be removed.
Illustration 4 g01301620
Remove bolts (8) and speed-timing wheel (7) from the camshaft drive gear.
Illustration 5 g01301623
Engage and lock the manual barring group to prevent the rotation of the crankshaft when bolt (10) is loosened. Note: To prevent damage to the camshaft timing pins, be sure to remove the pins when bolt (10) is loosened.
Use Tooling (C) and loosen bolt (10) on each camshaft.
Remove bolt (10) and washer (11).
Remove bolts (9) and plate (12) from camshaft drive gear (5).
Place washer (11) in position between the camshaft and plate (12). This position is shown in Illustration 5. Install bolt (10).
Install bolts (9) hand tight. Note: Be sure that bolt (10) is installed. This installation will prevent the camshaft drive gears from falling as the gears are loosened from the taper on the camshaft.
Tighten bolts (9) evenly to loosen camshaft drive gear (5) from the taper on the camshaft.
Attach a suitable lifting device to camshaft drive gear (5). The weight of camshaft drive gear (5) is approximately 35 kg (77 lb). Remove bolt (10).
Remove bolts (9) from plate (12) and washer (11).
Remove camshaft drive gear (5) from the rear housing.
Illustration 6 g00643311Note: Identify the proper orientation of the camshaft segments and the camshaft journals for installation purposes.
Install Tooling (A) under camshaft segment (4).
Remove bolts (1) that hold camshaft segment (4) in position.
Carefully move the front section of the camshaft toward the front of the engine to disengage the dowels in each end of the camshaft segment.
Carefully move camshaft segment (4) out of the engine on Tooling (A).
Attach a suitable lifting device to camshaft segment (4). The weight of camshaft segment (4) is approximately 30 kg (66 lb). Remove camshaft segment (4) from Tooling (A). Put identification marks on camshaft segment (4) for proper installation.
Remove the spacers from each camshaft journal (2). Remove Tooling (A) from the engine. Note: Later camshaft segments do not have spacers.
Remove bolts (3) that hold camshaft journal (2) to the other camshaft segment. Note: Later camshaft segments do not have spacers.
Slide camshaft journal (2) out of the camshaft bearing. Remove the camshaft journal from the engine. Remove the spacer from the journal.
Illustration 7 g01301637
Remove the bolts and plate (15) from shaft assembly (13).
Remove the bolts and plate assembly (14).
Remove the bolts that hold shaft assembly (13) to the camshaft segment. Remove shaft assembly (13).
Remove the spacer from shaft assembly (13).