96568M Mariner WIRE COMPLETE, STARTER LOCKOUT

Illustration 1 g01275318 (1) Bolt Apply 5P-3931 Anti-Seize Compound on the threads of the bolts before assembly. Torque ... 50 10 N m (37 7 lb ft) (2) Bolt Apply 5P-3931 Anti-Seize Compound on the threads of the bolts before assembly. Torque ... 120 20 N m (90 15 lb ft) (3) Housing Bore in housing for shaft bearings ... 25.875 0.013 mm (1.0187 .0005 inch)Outside diameter of shaft bearings ... 25.898 0.013 mm (1.0196 .0005 inch)Inside diameter of in-line shaft bearings ... 19.806 mm (0.7798 inch)Diameter of shaft ... 19.500 0.013 mm (.7677 .0005 inch) (4) Thrust washer Thickness ... 6.00 0.08 mm (.236 .003 inch) (5) Adjustable rod (6) Shaft Assemble the cross shaft with the end that is stamped "W/G END" toward the housing of the exhaust bypass valve. (7) Bolt Apply 5P-3931 Anti-Seize Compound on the threads of the bolts before assembly. Torque ... 50 10 N m (37 7 lb ft) (8) Actuator Torque of the nut for the actuator ... 200 20 N m (147.5120 14.7512 lb ft) (9) Outlet port (10) Inlet port Note: Assemble the actuator so the inlet port and the outlet port are aligned. This is shown in Illustration 1. The ports on the actuator are stamped" Inlet" and "Outlet". (11) Put 5P-3931 Anti-Seize Compound on the threads of the bolts before assembly. Torque ... 50 10 N m (37 7 lb ft) (12) Put 5P-3931 Anti-Seize Compound on the threads of the bolts before assembly. Torque ... 120 20 N m (90 15 lb ft) (13) Put 5P-3931 Anti-Seize Compound on the threads of the bolts before assembly. Torque ... 50 10 N m (37 7 lb ft) (14) Plate (15) Shaft (16) Mounting bolt Torque ... 14 3 N m (10 2 lb ft)
Illustration 2 g01275322
Exhaust bypass valve linkage
Closed position
(17) Nut torque ... 25 6 N m (18 4 lb ft)Assemble the plate to the shaft. Assemble the levers to the shaft and to the cross shaft. Use the woodruff keys to provide the proper orientation. Assemble and adjust the upper connecting rod to the correct distance.Distance between the rod ends of the upper connecting rod ... 349.2 1.0 mm (13.75 .04 inch)When the adjustable rod for the exhaust bypass valve is in the closed position the levers should be at angle (A). (A) Angle ... 75 degrees (18) Nut torque ... 25 6 N m (18 4 lb ft)Assemble the lever on the cross shaft. The lever should be located on the same side as the actuator. Use the woodruff key to assemble the lever. Assemble the linkage on the actuator. Check the distance between the rod end and the clevis when the actuator is in the extended position.Distance between the rod end and the clevis ... 117 mm (4.5 inch)Note: A final adjustment of the linkage is required. The adjustment of the linkage ensures that the plate does not contact the housing. In the closed position, contact the housing with the plate. The actuator should be fully extended. Shorten the length of the upper connecting rod by 1 turn. Lock the connecting rod in place.When the adjustable rod for the actuator is in the closed position the levers should be at angle (B). (B) Angle ... 36.4 degrees