860256A 3 Mercruiser HOUSING ASSEMBLY, Thermostat, Thermostat

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Loctite C5-A Copper Anti-Seize Lubricant -
B 195-4609 Seal Pick 1
C - Isopropyl Alcohol -
D 5P-4996 Plug 2 Start By:
Remove the exhaust elbow.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Turn the fuel supply to the OFF position and turn the power disconnect switch to the OFF.
Illustration 1 g02848517
Disconnect clamp assemblies (1) and remove hose (2).
Remove bolts (4), tube assembly (3), and the gasket. Discard the gasket.Note: Cap all hose assemblies, with Tooling (D), and fittings that are disconnected o prevent fluid loss. This action will also keep contaminants out of the systems.
Illustration 2 g02848516
Remove bolt (5) and disconnect harness assembly (6).
Illustration 3 g02848515
Disconnect hose assemblies (7) and hose assembly (8).
Remove allen bolt (9) and the clamp assembly. Position cable assembly (10) out of the way.
Disconnect flame detection temperature sensor (11).
Illustration 4 g02153382
Remove nuts (16) and combustion head (15).
Remove gasket (14), tube assembly (13), and gasket (12). Discard the gaskets.Note: The gaskets are for one time use only. Replace with new gaskets upon installation.
If required, remove studs (17).
Illustration 5 g03686649
Remove fittings (18) and (19).
Remove spark plug (20) and fittings (21).
Illustration 6 g02481277
Use Tooling (B) to remove O-ring seals (22) and (23) from cable assembly (10). Discard the O-ring seals.Installation Procedure
Install combustion head (15) in reverse order of removal.
Apply Tooling (A) to the threads of studs (17). Tighten studs (17) to a torque of 17 2 N m (150 18 lb in).
Apply Tooling (A) to the threads of the studs and nuts (16). Tighten nuts (16) in a crisscross pattern to a torque of 23 3 N m (204 27 lb in). Tighten nuts (16) again in a crisscross pattern to a torque of 28 3 N m (21 2 lb ft). Tighten nuts (16) again in a crisscross pattern to a torque of 28 3 N m (21 2 lb ft).
Use caution when you are using isopropyl alcohol. Avoid prolonged skin contact with isopropyl alcohol.Vapors may be harmful if inhaled. Use only in a well ventilated area. Do not smoke while using isopropyl alcohol.Isopropyl alcohol is flammable. Do not use near an open flame or near welding operations. Keep isopropyl alcohol away from heated surfaces exceeding 482°C (900°F).
Note: This connection is an electrical connection and cannot be lubricated with a petroleum-based lubricant. Isopropyl alcohol is the only approved lubrication for this connection.
Lubricate new O-ring seals (22) and (23) with Tooling (C) prior to installation.
Tighten fitting (21) to a torque of 60 6 N m (44 4 lb ft).
Tighten fittings (19) and (18) to a torque of 30 2 N m (266 18 lb in).
Tighten spark plug (20) to a torque of 57.5 4 N m (42 3 lb ft).
Apply Tooling (A) to the threads of flam