802625 Mercruiser O-RING

Table 1
Required Tools
Tool Part Number Part Description Qty
A 6V-6640 Gasket Maker 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. Refer to Systems Operation, Testing and Adjusting, "Turbacharger - Inspect" for more information. If the turbocharger is worn, the complete turbocharger must be replaced.
Illustration 1 g01264131
Typical example
Test the actuator (6) for correct operation. Refer to Systems Operation, Testing and Adjusting, "Turbacharger - Inspect". If the actuator is damaged or the actuator does not operate within the specified limits, the complete turbocharger must be replaced.
Clean the mating surfaces of the exhaust manifold. If necessary, install the studs to the exhaust manifold. Tighten the studs to a torque of 18 N m (13 lb ft).
Install a new gasket (7) to the exhaust manifold.
Position turbocharger (5) onto the exhaust manifold and install nuts (8). Tighten nuts (8) to a torque of 47 N m (35 lb ft). Note: Do not use the actuator rod to lift the turbocharger.
Position a new gasket (11) and tube assembly (13) onto turbocharger (5). Install bolts (12) finger tight.
Position a new gasket (15) onto the cylinder block. Install bolts (14) finger tight.
Tighten bolts (12) to a torque of 9 N m (80 lb in). Tighten bolts (14) to a torque of 22 N m (16 lb ft). If tube assembly (13) is secured with tube clips, tighten the fasteners for the tube clips to a torque of 44 N m (32 lb ft).
Lubricate the bearings of turbocharger (5) with clean engine oil through the oil inlet port. Rotate the shaft of the turbocharger in order to distribute the lubricant.
Position tube assembly (3) onto turbocharger (5). Install new washers (2) and banjo bolt (1) to tube assembly (3). Tighten the banjo bolt finger tight.
Install new washers (2) and banjo bolt (4) onto tube assembly (3). Connect the tube assembly to the cylinder block. Tighten the banjo bolt finger tight.
Tighten banjo bolt (1) and banjo bolt (4) to a torque of 18 N m (13 lb ft). Note: Ensure that the tube assembly does not come into contact with any other engine components.
Connect the hose to actuator (6). If necessary, secure tube assembly (3) to the tube assembly for actuator (6). Tube assembly (3) is secured to the tube assembly for the actuator by clips.
If the turbocharger is equipped with an adapter (9), position the adapter onto the turbocharger. Install nuts (10) finger tight.
If the turbocharger is equipped with an exhaust elbow, install the exhaust elbow. Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install".
If the turbocharger is equipped with an adapter (9), tighten nuts (10) progressively. Tighten nuts (10) to a torque of 44 N m (32 lb ft). Note: Ensure that the adapter is square with the mating face of the turbocharger.
Connect the air outlet hose to turbocharger (5). If the engine is equipped with an air pipe, install the air pipe and install the gasket to the cylinder head. Apply Tooling (A) to the fasteners for the air pipe. Tighten the fasteners to a torque of 22 N m (16 lb ft).Tighten the hose clamps to a torque of 5 N m (44 lb in).Note: If the air outlet hose has a reflective heat shield, ensure that the reflective heat shield is installed toward the engine.
Connect the air inlet hose to turbocharger (5).
If the valve mechanism cover is equipped with a heat shield, install the heat shield. Tighten the fasteners for the heat shield to a torque of 9 N m (80 lb in).