866594K01 Mercruiser FILTER, Fuel - Spin On

Table 1
Required Tools
Tool Part Number Part Description Qty
A 5R-7425 Barring Gp(1) 1
B 1P-1861 Retaining Ring Pliers 1
C 6V-4020 Piston Ring Expander 1
D 5P-8639 Hydraulic Press 1
8F-0024 Hose Assembly 1
1P-2375 Quick Connect Coupler 1
1P-2376 Quick Connect Coupler 1
1U-5230 Hand Hydraulic Pump 1
E 5P-8649 Adapter 1
F 6V-3043 Spacer 1
G 6V-3042 Adapter 1
(1) The 9S-9082 Engine Turning Tool is alternative tooling.Start By:
Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove".
Remove the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets - Remove and Install".
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: The front end of the engine is the end that is opposite of the flywheel. The number one cylinder is the right front cylinder and the number two cylinder is the front left cylinder.
Remove the cover from the front right side of the flywheel housing. Use Tooling (A) to rotate the flywheel until all four bolts in the connecting rod cap can be removed.
Mark the cylinder number on each connecting rod and on the corresponding connecting rod cap.
Illustration 1 g00913801
Illustration 2 g01051820
Remove bolts (1) and connecting rod cap (2) from connecting rod (5).
Remove the piston and connecting rod assembly.
Use Tooling (B) to remove the retaining rings that hold piston pin (4). Remove piston pin (4). Remove piston (3) from connecting rod (5).
Remove the bearings from connecting rod (5) and from connecting rod cap (2). Note: To help in the removal of the piston rings, separate the piston skirt from the piston crown.
Illustration 3 g00913818
Use Tooling (C) to remove piston rings (6) from piston (3).
Clean the piston ring grooves with an acceptable ring groove tool. Refer to Guideline For Reusable Parts, SEBF8059, "Procedure To Clean And Inspect 3500 Series Engine Pistons" for the correct procedure for cleaning the pistons.
Illustration 4 g01208346
Raise the temperature of connecting rod (5). Place Tooling (F) in the base plate of Tooling (D). Place connecting rod (5) on the base plate. Note: Do not use a direct flame in order to heat connecting rod (5).
Place the piston pin bearing in the center of the port assembly on Tooling (D). Install pin (9) in the center of the bore for the piston pin.
Install Tooling (E). Align the hole in Tooling (E) with the hole that is in the base plate of Tooling (D).
Install bar clamp (11) and clamp pin (10). Note: The old bearing is pushed out while the new bearing is installed.
Position Tooling (G) with the tapered side facing downward. The piston pin bearing joint must be aligned with the hole in Tooling (E) and the hole in the base plate of Tooling (D).
Place pusher (7) on Tooling (G).
Use Tooling (D) to push new piston pin bearing (8) into connecting rod (5) until Tooling (G) makes contact with connecting rod (5).
Remove connecting rod (5) and the old piston pin bearing from Tooling (D).
After the piston pin bearing is installed, measure the diameter of the bearing bore. The correct diameter is 70 0.01 mm (2.8 0.000 inch).