823902 Mercruiser COUPLING

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A (1)     9U-6195     Valve Spring Compressor     1    
416-0288 Head     1    
416-0292 Adapter     1    
( 1 ) C1.5 and C2.2Start By:
Remove the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove" for the correct procedure.
Personal injury can result from being struck by parts propelled by a released spring force.Make sure to wear all necessary protective equipment.Follow the recommended procedure and use all recommended tooling to release the spring force.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Install suitable plugs to the inlet ports of the cylinder head in order to prevent the entry of loose parts into the engine.
Plug the apertures for the push rods in the cylinder head in order to prevent the entry of loose parts into the engine.
Note: The removal procedure is similar for the three cylinder and the four cylinder engines. The following procedure should be adopted in order to remove the valve springs when the cylinder head is installed to the engine. Refer to Disassembly and Assembly, "Inlet and Exhaust Valves - Remove and Install" for the procedure to remove the valve springs from a cylinder head that has been removed from the engine.Note: Ensure that the appropriate piston is at the top center position before the valve spring is removed. Failure to ensure that the piston is at the top center position may allow the valve to drop into the cylinder bore.
Illustration 1 g03341307
Follow Step 1.a through Step 1.d in order to position the appropriate piston at top center.
Install Tooling (A) in position on the cylinder head in order to compress a valve spring for the appropriate piston.
Use Tooling (A) in order to compress valve spring (3) and open the valve slightly.Note: Do not compress the spring so that the valve spring retainer (2) touches the valve stem seal.
Carefully rotate the crankshaft until the piston touches the valve.Note: Do not use excessive force to turn the crankshaft. The use of force can result in bent valve stems.
Continue to rotate the crankshaft and gradually release the pressure on Tooling (A) until the piston is at the top center position. The valve is now held in a position that allows the valve spring to be safely removed.
Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.
Note: For four cylinder engines, if all valve springs require replacement the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairs of cylinders. 1 with 4 and 2 with 3. Ensure that all of the valve springs are installed before changing from one pair of cylinders to another pair of cylinders.
Apply sufficient pressure to Tooling (A) in order to allow removal of the valve keepers (1) .Note: Do not compress the spring so that the valve spring retainer (2) touches the valve stem seal.
Remove valve keepers (1) .
Slowly release the pressure on Tooling (A) .
Remove valve spring retainer (2) and remove valve spring (3) .
Remove Tooling (A) .Installation Procedure
Table 2
Required Tools    
Tool     Part Number     Part Description     Qty    
A (1)     9U-6195     Valve Spring Compressor     1    
416-0288 Head     1    
416-0292 Adapter     1    
( 1 ) C1.5 and C2.2
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.