865596T01 Mercruiser BRACKET, Idler Pulley

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0510 Driver Gp 1
B - Loctite LB 8028 Camshaft Lube -
C - Loctite Superflex Silicone Adhesive Sealant, Blue -
D - Loctite 242 -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine.
Thoroughly clean the gasket material from the cylinder block and both sides of the plate.
Illustration 1 g01101567
If studs (24) are loose or the threads are damaged, install new studs (24) in the front plate. Apply Tooling (D) to the serrations of studs (24). Install studs (24) in the front plate.
Install integral seal (25) on the dowel pins on the cylinder block.Note: Apply Tooling (C) to the bottom of integral seal (25) in order to fill the space at the cylinder block, the front housing, and the engine oil pan.
Install plate (22) on the dowel pins on the cylinder block. Install new locking bolts (23) (Marked "X") in order to fasten the front plate to the cylinder block. Tighten locking bolts (23) to a torque of 55 N m (41 lb ft).Note: Clean the old sealant from the bolts and apply Tooling (D) to the bolts.
Tighten locking bolts (23) again to a torque of 55 N m (41 lb ft).
Illustration 2 g01239343
Install stub shaft (18). Apply Tooling (D) to the studs and the bolt for stub shaft (18). Tighten nuts (19) and the bolt to a torque of 55 10 N m (41 7 lb ft).
Install stub shaft assembly (16). Apply Tooling (D) to the studs and the bolt for stub shaft assembly (16). Do not tighten nuts (17) and the bolt for stub shaft assembly (16) at this time. Nuts (17) and the bolt for stub shaft assembly (16) will need to be tightened when the backlash is adjusted.
Adjust the backlash between the camshaft gear and the adjustable idler gear assembly. The backlash should be 0.356 0.254 mm (0.014 0.010 inch). Refer to Testing and Adjusting, "Gear Group (Front) - Time" for the backlash adjustment procedure. Tighten nuts (17) and the bolt to a torque of 55 10 N m (41 7 lb ft).
Install stub shaft (20). Apply Tooling (D) to bolts (21). Install bolts (21) and tighten in a numeric sequence 1, 3, 4, 5, 2, 1, 2, 3, 4, 5, 1 to a torque of 55 10 N m (41 7 lb ft).
Illustration 3 g01239302
Use Tooling (A) to install the sleeve bearing in cluster gear assembly (13).
Put cluster gear assembly (13) on the stub shaft. Ensure that Timing Marks (V) are aligned on the cluster gear assembly and the crankshaft gear.
Position plate (15) with the oil groove toward the face of the gear. Apply Tooling (D) to bolts (14). Install bolts (14). Tighten bolts (14) to a torque of 30 7 N m (22 5 lb ft).
Illustration 4 g01239267
Use Tooling (A) to install the sleeve bearing in idler gear (10) and adjustable idler gear (7).Note: Align the oil hole in the bearing with the oil hole in the adjustable idler gear.
Put idler gear assembly (10) on the stub shaft. Install plate (12) with the oil groove toward the gear face. Apply Tooling (D) to bolts (11). Install bolts (11). Tighten bolts (11) to a torque of 30 7 N m (22 5 lb ft).
Put adjustable idler gear assembly (7) on the stub shaft assembly. Position plate (9) with the oil groove toward the face of the gear. Apply Tooling (D) to bolts (8). Install bolts (8). Tighten bolts (8) to a torque of 30 7 N m (22 5 lb ft).Note: Check the backlash for the camshaft gear and the adjustable idler gear assembly. The camshaft gear must be installed and the adjustable idler gear assembly must be removed in order to perform the backlash adjustment procedure. Refer to Testing and Adjusting, "Gear Group (Front) - Time".
Illustration 5 g01008431
Install O-ring seal (5) and O-ring seal (6) in sealing plate (3). Lubricate O-ring seal (6) with a 50/50 mixture of Tooling (B) and clean engine oil.
Illustration 6 g01008430
Illustration 7 g01008429
Install adapter (4). Ensure that the dowel in the adapter engages the hole in the camshaft.