808539 Mercruiser NUT (1/4-20)

1. Loosen the clamp that holds hose (4) in position. Remove hose (4).2. Remove the bolts that hold elbow (3) to the timing gear cover. Disconnect the elbow from the timing gear cover.3. Remove alternator mounting bracket (2).4. Turn off the fuel supply at the fuel tank.5. Disconnect two fuel lines (1) at the fuel injection pump. 6. Loosen the clamp that holds hose (5) to the elbow. Remove the tube and hose (5) from the elbow.7. Disconnect the wire harnesses from two switches (6).8. Disconnect the other end of fuel lines (1) from the fuel filter.9. Remove the bolts and clips that hold fuel lines (1) and the wire harnesses to the timing gear cover. Remove the fuel lines. 10. Remove tube assembly (8).11. Loosen hose clamp (7).12. Disconnect tube assembly (10) from the ether starting aid.13. Disconnect the wire harness from the ether starting aid.14. Remove the bolts and bracket assembly (9). 15. Remove tube assembly (11) from the oil pump. 16. Put a wood block and tooling (A) in position under the cylinder block as shown.17. Remove bolt (13).18. Use tooling (A) to support the weight of the engine. Remove the bolts and support assembly (12) from the front of the engine. 19. Remove bolts (14) and (15) from the rear of the timing gear cover. 20. Fasten a hoist and tooling (B) to timing gear cover (16). Remove the bolts that hold the timing gear cover to the engine. Remove the timing gear cover and the gasket. The weight of the timing gear cover is 43 kg (95 lb).21. Remove the water ferrule, seal and the clamp from the timing gear cover.Install Timing Gear Cover
1. Check the condition of the water ferrule and seal, and replace them if necessary. Put the water ferrule and seal in position with the adjusting screw of the hose clamp toward the top and approximately 45° to the right of the vertical centerline as seen from the front of the engine. Make sure the seal is installed all the way in the counterbore. 2. Fasten a hoist and tooling (A) to timing gear cover (1). Put the gasket and timing gear cover in position on the front of the engine, and install the bolts that hold it in place. Cut the gasket even with the bottom of the cylinder block. 3. Install bolts (2) and (3). 4. Put support assembly (4) in position on the timing gear cover, and install the bolts that hold it in place.5. Use tooling (B) to lower the engine. Install bolt (5). Remove tooling (B). 6. Install tube assembly (6) on the oil pump. 7. Tighten hose clamp (7).8. Install tube assembly (8).9. Put bracket assembly (9) in position, and install the bolts that hold it.10. Connect tube assembly (10) to the ether starting aid.11. Connect the wire harness to the ether starting aid. 12. Put the tube assembly and hose (11) in position on the elbow, and tighten the clamp that holds them in place.13. Connect the wire harnesses to two switches (12).14. Connect two tube assemblies (13) to the fuel filter.15. Install the clips and bolts that hold the wire harness and tube assemblies (13) in position on the timing gear cover. 16. Connect tube assemblies (13) to the fuel injection pump.17. Put the gasket and elbow (15) in position on the timing gear cover, and install the bolts that hold them in place.18. Put hose (16) in position, and tighten the clamp that holds it in place.19. Install alternator mounting bracket (14).20. Turn the fuel supply at the fuel tank.End By:a. install oil panb. install crankshaft front pulleyc. install belt tightenerd. install alternatore. install fan and fan drivef. install radiator