864395T Mercruiser HEAT EXCHANGER, Closed Cooling

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0520 Driver Gp 1
B - Guide Stud
5/8 - 18 by 12 inch 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Prior to rear gear group installation, inspect the screens integral to the external lubrication adaptors (Part # 297-7956) located in the housing. Clean or replace adaptors as needed. Part is non-serviceable. Proper inspection/cleaning and or replacing the external lubrication adaptors will prevent contamination of the rear gear group.
Note: Apply clean engine oil to the bearings and the shaft assemblies prior to installation on the engine.
Illustration 1 g01151842
Install the O-ring seals and the sealing plates on the cylinder head.
Install adapter assemblies (15), thrust plates (14), and bolts (13).
Position shaft assembly (17) and install bolts (16).
Illustration 2 g02087918
Illustration 3 g02087895
(X) Marker
(Y) Alignment Mark
Illustration 4 g02088394
Illustration 5 g01151468Note: Align the timing marks on gear assemblies (4) with the timing marks on the rear housing and align the dowels on gear assemblies (4) with the adapter assemblies.
Position gear assemblies (4) and install bolts (5).
Install Tooling (B) in the crankshaft. Install gear assembly (12).
If the top center position is already marked on the vibration damper, proceed to Step 7.
Install the flywheel housing and the flywheel temporarily. Two bolts in the flywheel housing and the flywheel are sufficient.
Position the number one piston in the top center position (TC). The engine should be at the top center position to install the rear gear group. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".
With the number one piston in the top center position (TC), attach a marker to the engine and place an Alignment Mark on the vibration damper.
Remove the flywheel and the flywheel housing.
Install two nuts on two bolts for the flywheel (18). The nuts will provide spacing when the bolts are installed. Install two bolts for the flywheel (18) in gear assembly (12).
Use Tooling (A) and a suitable press to install the bearing in gear assembly (1). Install the bearing to a depth of 2.6 0.5 mm (0.10 0.02 inch). The bearing must be machined once installed into the gear. Refer to Reuse and Salvage Guidelines, SEBF9244 for the correct after machining dimension and surface requirements.
Install shaft assembly (3), gear assembly (1), and bolts (2). Tighten the bolts (2) to a torque of 55 10 N m (41 7 lb ft).
Use Tooling (A) and a suitable press to install the bearing in gear assembly (6). Install the bearing to a depth of 2.6 0.5 mm (0.10 0.02 inch). The bearing must be machined once installed into the gear. Refer to Reuse and Salvage Guidelines, SEBF9244 for the correct after machining dimension and surface requirements.
Install shaft assembly (7), gear assembly (6), and bolts (8).
Use Tooling (A) and a suitable press to install the bearing in gear assembly (9). Install the bearing to a depth of 3.2 0.5 mm (0.13 0.02 inch). The bearing must be machined once installed into the gear. Refer to Reuse and Salvage Guidelines, SEBF9244 for the correct after machining dimension and surface requirements.Note: Ensure that the number one piston is in the top center position (TC).Note: Align the timing mark on gear assembly (9) with the timing mark on gear assembly (12).
Install gear assembly (9), thrust plate (11), and bolts (10).
Tighten the bolts on gear assemblies (4) to a torque of 240 40 N m (177 30 lb ft). Tighten the bolts in the following sequence: 1, 4, 2, 5, 3, 6, 1, 4.End By:
Install the flywheel housing.C32 Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 1P-0520 Driver Gp 1
B - Guide Stud
5/8 - 18 by 12 inch 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.