63990 Mercruiser INSLUATOR, SWITCH AND SENDER

Table 1
Required Tools
Tool Part Number Part Description Qty
A 6V-6640 Sealant 1
B - Guide Studs
M8 by 80 mm 2
C 319-6486 Alignment Tool 1
- Bolts
M10 by 50 mm 3
D 1U-6396 O-Ring Assembly Compound 1
E 7M-7456 Bearing Mount Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the wiring harness assembly is correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness and the convoluting.
Ensure that the front housing is clean and free from damage. If necessary, replace the front housing. If necessary, install blanking plugs to a new front housing. Use Tooling (A) in order to seal all D-plugs.
Clean all the gasket surfaces of the cylinder block.
Illustration 1 g02490396
Illustration 2 g02490397
Inspect dowel (17) and dowel (18) for damage. If necessary, replace the dowels in the cylinder block.
Install thrust washer (15) into the recess in cylinder block (16). Refer to Disassembly and Assembly, "Camshaft - Install" for more information.
Install Tooling (B) to cylinder block (16). Refer to Illustration 2.
Align a new gasket (10) with Tooling (B). Install the gasket to (16) cylinder block. Note: Ensure that two circular Tabs (X) on the gasket are engaged in two Holes (Y) in cylinder block (16). Ensure that dowel (18) in cylinder block (16) is engaged on the gasket.
Install Tooling (C) to cylinder block (16).
Illustration 3 g02490399
If necessary, follow Step 8.a through Step 8.c in order to install bearing (10) to housing (7).
Apply a small continuous bead of Tooling (E) to outer Surface (Z) of bearing (10).
Place housing (7) onto a suitable support.
Use a suitable tool in order to press bearing (10) into housing (7) until the bearing is in the correct position within the housing. Remove any excess bearing mount compound.
Install the front housing over Tooling (B) and Tooling (C) onto cylinder block (16).
Illustration 4 g02490400
(11) M8 by 35 mm
(12) M8 by 20 mm
(13) M8 by 25 mm
Illustration 5 g02058297
Install bolts (13) to front housing (7) finger tight.
Remove Tooling (B).
Loosely install bolts (11) and bolts (12). Refer to Illustration 4 for the correct position of the bolts.
Tighten bolts (11), bolts (12) and bolts (13) in the sequence that is shown in Illustration 5 to a torque of 28 N m (248 lb in).
Remove Tooling (C) from the cylinder block.
Illustration 6 g02490356
Install a new O-ring seal (8) and a new O-ring seal (9) to bypass tube (5). Use Tooling (D) in order to lubricate the O-ring seals.
Install bypass tube (5) to the cylinder head. Install bolts (6). Tighten the bolts to a torque of 9 N m (80 lb in).
Connect harness assembly (2) to coolant temperature sensor (3).
Slide locking tab (1) (not shown) into the locked position.
Position harness assembly (2) onto bypass tube (5). Install a new cable strap (4). Note: Ensure that the cable strap meets Original Equipment Manufactures (OEM) specification.End By:
Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install" for the correct procedure.
Install the timing gears. Refer to Disassembly and Assembly, "Gear Group (Front) - Install" for the correct procedure.
If the engine has an accessory drive, install the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive - Remove and Install" for the correct procedure.
Install the engine oil pan . Refer to Disassembly and Assembly, "Engine Oil Pan - Install" for the correct procedure.
Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley - Install" for the correct procedure.
Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install" for the correct procedure.
Install the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install" for the correct procedure.
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Fill" for the correct procedure.