809138 Mercruiser THRU BOLT

START BY:a. remove valve cover 1. Use tool (A), and remove fuel lines (1). Put caps over all open fuel lines. 2. Disconnect fuel lines (2) from the fuel line adapters. 3. Remove nuts (3), the washers and adapters (4) from the valve cover base. 4. Loosen four bolts (5) evenly, and remove the bolts and rocket shaft assembly (6) from the engine.Install Rocker Shaft Assembly
1. Put rocker shaft assembly (1) in position on the head. Make sure the rocker arm and push rods are in alignment before the bolts that hold the rocker shafts in position are tightened.2. Put clean engine oil on the threads of rocker shaft assembly bolts (2) through 5. Tighten bolts (2) through 5 in number sequence to a torque of 270 25 N m (200 20 lb.ft.). Tighten bolts again in number sequence to a torque of 447 20 N m (330 15 lb.ft.). Tighten the bolts again in number sequence to a torque of 447 20 N m (330 15 lb.ft.). 3. Put clean engine oil on O-ring seals (8). Install the spacers, fuel line adapters (6) and locks (7).4. Install the nuts, and tighten to a torque of 14 3 N m (10 2 lb.ft.). 5. Connect fuel lines (9) to the fuel line adapters, and tighten the nuts to a torque of 40 7 N m (30 5 lb.ft.).6. Install fuel lines (10) to the fuel line adapters as shown. Tighten the nuts to a torque of 40 7 N m (30 5 lb.ft.). Use tool (A) to tighten the lower nuts as shown.7. Make an adjustment of the valves to have a clearance of 0.38 mm (.015 in.) for intake and 0.76 mm (.030 in.) for exhaust. See Valve Clearance Setting in Testing And Adjusting.END BY:a. install valve coversDisassemble Rocker Shaft Assembly
START BY:a. remove rocker shaft assembly 1. Remove retainer (1) from the end of the shaft.2. Remove the washers and rocker arm (2). 3. Use tool (A) to remove the pin that holds bracket (3) to the rocker arm shaft.4. Remove bracket (3), rocker arm (4) and the spring.5. Remove the remainder of the rocker arms. The center brackets do not have pins.Assemble Rocker Shaft Assembly
Make sure all parts of the rocker shaft assembly are clean before assembly. 1. Put clean engine oil on shaft (3).2. Install the center springs, rocker arms and bracket.3. Install spring (1), rocker arm (4) and bracket (2).4. Put tape around the shaft on each side of bracket (2) as shown. Put the hole in bracket (2) in alignment with the hole in shaft (3). Put a mark on each piece of tape in alignment with the hole in bracket (2).5. Install pin (5) until it is extended 8.6 mm (.34 in.) above the surface of bracket (2). Make sure pin (5) is in alignment with the marks on the tape before pin is installed. Remove the tape. 6. Install rocker arm (6), washers (7) and retainer (8). Install enough washers until the end play on each end of the shaft is 0.12 - 1.01 mm (.005 - .005 in.).END BY:a. install rocker shaft assembly