7499 Mercruiser CYLINDER HEAD ASSEMBLY

Table 1
Required Tools
Tool Part Number Part Description Qty
A 185-3996 Thread Lock Compound Loctite 243 1
Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more information. If the turbocharger is worn, the complete turbocharger must be replaced.
Test the turbocharger actuator for correct operation. Refer to Systems Operation, Testing and Adjusting, "Wastegate - Test" for more information. If the actuator is damaged or the actuator does not operate within the specified limits, the complete turbocharger must be replaced.
Illustration 1 g03818515
Typical example
Illustration 2 g03818608
Typical example
Illustration 3 g03851119
Typical example
Clean the gasket surface of the exhaust manifold and the gasket surface of turbocharger (4).
If necessary, install the studs to the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install" for the correct procedure.
If necessary, install bolts (11) to turbocharger (4). Tighten the bolts to a torque of 25 N m (221 lb in).
Position a new gasket (7) (not shown). onto the exhaust manifold.
Install turbocharger (4) to the exhaust manifold.Note: Do not use the actuator rod to lift the turbocharger.
Install nuts (6) to turbocharger (4). Support the weight of the turbocharger as the nuts are installed finger tight.
Temporarily install the exhaust elbow to ensure the correct alignment with the turbocharger and Clean Emissions Module (CEM). Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install (Exhaust Elbow between the Turbocharger and the Clean Emissions Module (CEM))" for the correct procedure.
Tighten the three accessible nuts (6) to a torque of 25 N m (18 lb ft).
Remove the exhaust elbow and tighten the remaining nut (6) to a torque of 25 N m (18 lb ft).
Ensure that tube assembly (14) is free from restriction and damage.
Install a new gasket (12) (not shown) onto tube assembly (14).
Position tube assembly (14) onto turbocharger (4). Install bolts (13) finger tight.
Position a new gasket (15) (not shown) between tube assembly (14) and the cylinder block. Install bolts (16) finger tight.
Tighten bolts (13) and bolts (16) to a torque of 10 N m (89 lb in).
Lubricate the bearings of turbocharger (4) with clean engine oil through the oil inlet port. Rotate the shaft of the turbocharger to distribute the lubricant.
Install a new sealing washer (10) (not shown) onto banjo bolt (9).
Install banjo bolt (9) to tube assembly (8). Install a new sealing washer (10) (not shown) between tube assembly (8) and turbocharger (4).
Position a new gasket (25) (not shown) between tube assembly (8) and the cylinder block. Install bolts (24) finger tight.
Position bracket (23) for tube assembly (8) and install the bolt finger tight.
Position bracket (22) for tube assembly (8) and install the bolt finger tight.
Tighten banjo bolt (9) to a torque of 18 N m (159 lb in).
Tighten bolts (24) to a torque of 10 N m (89 lb in).
Tighten the bolt for bracket (23) to a torque of 10 N m (89 lb in).
Tighten the bolt for bracket (22) to a torque of 10 N m (89 lb in).
Apply Tooling (A) to bolt (21A). Position engine lifting bracket (21) onto the cylinder head and install bolt (21A) Tighten the bolt to a torque of 50 N m (37 lb ft).
Install wiring harness assembly into the original position.
Install breather assembly (17) to bracket (20). Refer to Disassembly and Assembly, "Crankcase Breather - Remove and Install" for the correct procedure.
Illustration 4 g03818463
Typical example
Ensure that hose assembly (3) is free from restriction or damage.
Ensure that hose clamp (2) and hose clamp (5) (not shown) are correctly positioned onto hose assembly (3).
Install hose assembly (3) to the inlet for turbocharger (4) and inlet tube assembly (1).
Tighten hose clamp (2) and hose clamp (5) for hose assembly (3) securely.End By:
Install the exhaust elbow. Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install (Exhaust Elbow between the Turbocharger and the Clean Emissions Module (CEM))" for the correct procedure.