809068 Mercruiser METERING ROD KIT

Start By:a. remove radiator guard and support 1. Disconnect hose assembly (2) from fan pulley hub (1). 2. Disconnect hose assembly (4) from tightener arm assembly (3).
V-belts (6) are under tension from spring (5). If wrench slips while releasing the belt tension, personal injury may result. Be sure wrench is properly engaged with the belt tightener.
3. Using Tooling (A) release the tension on spring (5) and remove V-belts (6) from tightener arm assembly pulley (7). 4. Remove bolt (9) and the washer from fan support block (8). 5. Remove full nut (11), the washer, and spring retainer (12) from bracket assembly (10). 6. Loosen, but do not remove bolt (13), the washers, and the nut from filter bracket assembly (14).7. Position a lifting sling around fan pulley hub (1) as shown. Secure the lifting sling to a hoist. Remove three bolts (15), the washers, and fan drive (16) from the front engine housing. The weight of fan drive (16) is 95 Kg (210 lb). The following steps are for the installation of the fan drive and belt tightener.8. Make sure all components of the fan drive and belt tightener are clean of dirt and foreign material prior to installation.9. Check all components for wear or damage and replace if necessary. 10. Position a lifting sling around fan pulley hub (1) as shown. Secure the lifting sling to a hoist. Install fan drive (16), three bolts (15), and the washers to the front engine housing. The weight of fan drive (16) is 95 Kg (210 lb).11. Tighten bolt (13), the nut, and the washers to filter bracket assembly (14). 12. Put spring retainer (12) in position in bracket assembly (10), as shown. Install the washer, and full nut (11). 13. Install bolt (9) and the washer to fan support block (8).
V-belts (6) are under tension from spring (5). If wrench slips while installing the belt tension, personal injury may result. Be sure wrench is properly engaged with the belt tightener.
14. Using Tooling (A) release the tension on spring (5) and install V-belts (6) to tightener arm assembly pulley (7). 15. Connect hose assembly (4) to tightener arm assembly (3). 16. Connect hose assembly (2) to fan pulley hub (1).End By:a. install radiator guard and supportDisassemble & Assemble Fan Drive & Belt Tightener
Start By:a. remove fan drive and belt tightener 1. Put two lifting slings in position around the fan drive and belt tightener as shown. Secure the lifting slings to a hoist. Put the fan drive and belt tightener on wood block as shown. Remove two bolts (1), the washers, and block (2) from the fan drive and belt tightener. The weight of the fan drive and belt tightener is 95 Kg (210 lb). 2. Remove bolt (3), the washer, retainer plate (4), and belt tightener (5) from bracket assembly (6).3. Refer to the topic "Disassemble & Assemble Belt Tightener" in this module, for disassembly and assembly procedures of belt tighter (5) 4. Put two lifting slings in position around fan drive pulley (9) as shown. Secure the lifting slings to a hoist. Remove six bolts (7) from fan pulley hub (8). Remove fan drive pulley (8) from fan pulley hub (6). 5. Remove eight bolts (10) and fan adapter (11) from fan pulley hub (8). 6. Remove two locking bolts (12) and washer (13) from fan pulley hub (8). 7. Remove fan pulley hub (8) from bracket assembly (6). 8. Remove spacer (14) from fan pulley hub (8). 9. Using Tooling (A) remove lip seal (15) from fan pulley hub (8). 10. Remove ball bearing (16) from fan pulley hub (8). 11. Turn fan pulley hub (8) over as shown. Remove O-ring seal (18) from fan pulley hub (8). Using Tooling (B), remove ball bearing (17) from fan pulley hub (8). 12. Remove sleeve (19) from fan pulley hub (8). If necessary remove pipe plug (20) from fan pulley hub (8). 13. If necessary remove dowel (23), dowel (24) (not shown), fan shaft (22), tightener shaft (21), and pipe plug (25) from bracket assembly (6). The following steps are for the assembly of the fan drive and belt tightener.14. Make sure that all the components of the fan drive and belt tightener are clean of dirt and foreign material prior to assembly.15. Check all O-ring seals and components for wear and damage and replace if necessary. 16. Install fan shaft (22), tightener shaft (21), dowel (23), dowel (24) (not shown), and pipe plug (25) to bracket assembly (6).
Install spacer (19) with the grooved end toward top of fan pulley hub (8) as shown. Failure to do so could result in fan drive and belt pulley failure.
17. Install spacer (19) in fan pulley hub (8). Install pipe plug (20) in fan pulley hub (8). Fill the cavity between spacer (19) and fan pulley hub (8) with 1P-0808 Grease. 18. Using Tooling (C), install ball bearing (17) in fan pulley hub (8). Install O-ring seal (18) in fan pulley hub (8). 19. Turn fan hub (8) over, as shown. Install ball bearing (16) in fan pulley hub (8). Install lip seal (15) with the open end facing up.20. Using Tooling (C), install lip seal (15) in fan pulley hub (8). Lubricate lip seal (15) lightly with the lubricant being sealed. Install sleeve (14) with the large chamfer towards the bearing.21. Install sleeve (14) in fan pulley hub (8). 22. Install fan pulley hub (8) on bracket assembly (6). 23. Install washer (13) and two locking bolts (12) on fan pulley hub (8). Tighten two locking bolts (13) to a torque of 105 20 N m (77 15 lb ft). 24. Using Tooling (C) install fan adapter (11) on fan pulley hub (8). 25. Install eight bolts (10) that hold fan adapter (11) to fan pulley hub (8). Tighten eight bolts (10) to a torque of 47 9 N m (35 7 lb ft).