864398T04 Mercruiser HOUSING ASSEMBLY, Thermostat

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g03409484
If suction pipe (5) has a support bracket, remove bolt (7) from bracket (8). Remove bolt (6) for the retaining clip.
Remove bracket (8). Note: Note the position and orientation of the components for the support bracket.
Remove bolts (4) from suction pipe (1).
Remove suction pipe (5) from oil pump (2).
Remove gasket (3) (not shown).
Remove bolts (1) and remove the assembly of engine oil pump (2) from the cylinder block.
Illustration 2 g03409496
If necessary, follow Step 7.a through step 7.c to disassemble engine oil pump assembly (2).
Remove bolts (11).
Remove front cover assembly (12) from engine oil pump assembly (2).
Make temporary mark on outer rotor (13) for assembly purposes. Remove the outer rotor from of engine oil pump (2).
Do not remove dowel (9) or dowel (10) from the housing of the engine oil pump unless the dowels are damaged.
Illustration 3 g03409497
If necessary, follow Step 9.a through step 9.c to remove cross over tube assembly (14).
Remove bolts (15) and bolts (16) from cross over tube assembly (14).
Remove cross over tube assembly (14) from the cylinder block.
Remove gasket (17) and gasket (18). Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 7H-1942 Dial Indicator 1
- Magnetic Base and Stand 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
If any part of the engine oil pump is worn or damaged, the complete assembly of the engine oil pump must be replaced.
Ensure that all components of the engine oil pump are clean and free from wear and damage. Refer to System Operation, Testing and Adjusting, "Engine Oil Pump - Inspect" for more information. Replace the complete assembly of the engine oil pump if any of the components are worn or damaged.
Illustration 4 g03409497
If necessary, follow Step 2.a through step 2.d to install cross over tube assembly (14).
Install new gasket (17) and new gasket (18).
Position cross over tube assembly (14) onto the cylinder block.
Install bolts (15) and bolts (16) to cross over tube assembly (14) finger tight.
Tighten bolts (15) and bolts (16) to a torque of 22 N m (195 lb in).
Illustration 5 g03409496
If necessary, follow Step 3.a through step 3.d to assemble engine oil pump assembly (2).
Lubricate the internal components for the assembly of the engine oil pump with clean engine oil.
Install outer rotor (13) to oil pump assembly (2). Ensure that the outer rotor is installed in the outer rotor original position and orientation.
Install front cover assembly (12) to engine oil pump assembly (2).
Install bolts (11) finger tight. Tighten the bolts to a torque of 22 N m (195 lb in).
Ensure that dowel (9) and dowel (10) are correctly located in the housing of engine oil pump (2).
Install bolts (7). Tighten the bolts to a torque of 22 N m (195 lb in).
Install the assembly of engine oil pump (2) to the cylinder block. Ensure that dowel (9) and dowel (10) are correctly aligned with the holes in the cylinder block.
Install bolts (1) to assembly of engine oil pump (2). Tighten the bolts to a torque of 22 N m (195 lb in).
Use Tooling (A) to check the backlash between idler gear and the crankshaft gear. Refer to Specifications, "Gear Group (Front)" for more information.
If suction pipe (5) had a support bracket, Follow Step 9.a through Step 9.e in order to install support bracket and the suction pipe.
Install a new gasket (3) (not shown) to suction pipe (5).
Install bolts (4) to suction pipe (1).
Position the assembly of suction pipe (5) onto oil pump (2). Tighten bolts (4) to a torque to 22 N m (195 lb in).
Position bracket (8) onto cylinder block and retaining clip. Install bolt (7) to the bracket. Install bolt (6) to the retaining clip. Hand tighten the bolts. Note: Ensure the correct location and orientation of the bra