805837 Mercruiser PIPE

2. Disconnect clips (1) from the air compressor and block.3. Remove tube assembly (2) from the air compressor and cylinder block. 4. Remove water lines (3), (4) and (5) from the air compressor.
Before any lines are disconnected from the air compressor, make sure the air pressure is zero.
5. Disconnect air lines (6) and (7) from the air compressor. 6. Remove nuts (8). Use two persons to remove air compressor (9). The weight of the air compressor is 55 lb. (25 kg).Install Air Compressor
1. Install a new gasket on the air compressor. Use two persons to put air compressor (1) in position on the flywheel housing. Install the nuts that hold it. 2. Connect air lines (2) and (3) to the air compressor. 3. Install water lines (4), (5) and (6). 4. Install tube assembly (8) on the cylinder block and air compressor.5. Connect clips (7) to the air compressor and block.6. Fill the cooling system with coolant to the correct level. See LUBRICATION AND MAINTENANCE GUIDE.Remove Accessory Drive
start by:a) remove air compressor 1. Remove nut (4) from the compressor drive shaft with tool (A). Remove spacer (3).2. Remove O-ring seal (2) from adapter (1). 3. Remove drive gear (5) from the compressor drive shaft with tool (B). Remove the key from the shaft.4. Remove the adapter and gasket (6).Install Accessory Drive
1. Install the key on air compressor drive shaft (1).2. Install gasket (5) and adapter (6) on the air compressor.3. Put the groove in the drive gear in alignment with the key in the drive shaft. Install gear (2) on the shaft. 4. Install spacer (3) and nut (4) on the drive shaft. Tighten the nut with tool (A).5. Install O-ring seal (7) on the adapter. end by:a) install air compressorDisassemble Air Compressor
start by:a) remove air compressorb) remove accessory drive1. Remove the water line elbow, the air line elbows and oil (drain) tube from the air compressor. 2. Remove bolts (1) from the cylinder head. Remove cylinder head (2) and the gasket from the crankcase. 3. Remove inlet valve springs (7).4. Remove (discharge) valve seats (6) from the cylinder head. Remove valves (8) and springs (5).5. Inspect the valve seats for damage and wear. Make replacements if necessary. 6. Remove valve stops (9) as follows: a) Put the machined surface of the cylinder head down on an arbor press.b) Gradually push the stops from the top of the cylinder head and out of the bottom.c) Be sure there is enough clearance for the stops between the press and the bottom of the cylinder head.d) Inspect the stop bore in the cylinder head. Make a replacement of the head body if the bore is damaged. Remove the valve stops only if there is wear and damage, also if the valve movement (travel) exceeds .057 in. (1.45 mm).7. Remove bolts (3) from the adapter. Remove adapters (4) from the compressor housing. 8. Remove O-ring seal (10), the thrust washer and the bearing from the adapter with tool (A).9. Remove bolts (12) from the cover. Remove cover (11) and the gasket from the crankcase. 10. Bend down the lock on lock straps (13). Remove bolts (14) from the bearing caps.11. Put identification on the bearing caps for correct installation with the connecting rod. Remove the bearing caps. 12. Remove pistons (15) from the crankcase through the top of the cylinders.13. Remove crankshaft (16) from the crankcase. Remove the key from the crankshaft. 14. Remove end cover (17) from the crankcase. Remove the O-ring seal, the thrust washer and the bearing.15. Remove cover (18), the gasket and the strainer from the air inlet opening.16. Remove inlet valves (20) from their guides (21). Remove the inlet valve guides from around the inlet valve seats.
Be careful not to cause damage to the inlet valve seats.
17. Remove (unloader) spring (19), spring saddle (22) and the spring seat from the housing with needle nose pliers.18. Remove (unloader) plunger (24) and guides (25) from the housing. Remove the guides from the plungers to plungers. 19. To remove (unloader) pistons (23) from the bore, put a cover over the inlet port, then blow air pressure in the governor mounting pad (unloader) port. 20. Remove lockpin (27) that holds rod pin (26) in the piston. Remove the pin from connecting rod (28). 21. Remove the piston rings from piston (30). Remove two compression rings (29), the oil ring and the expander ring with tool (B).22. Remove the bearings from the connecting rod and the connecting rod cap. 23. Remove the piston pin bushing with tool (C).24. Remove the small seal rings from both ends of the housing.25. Clean all the oil passages through the housing, the crankshaft, the end cover and the adapter.Assemble Air Compressor
1. Check (unloader) bore bushings (1) for damage and wear. If these bushings need replacement, remove the bushing by the use of a 1/8 in. (3.18 mm) pipe threaded tap. Then install a 1/8 in. (3.18 mm) pipe threaded rod and pull the bushing straight up and out.2. Check the cylinder bores in the crankcase housing for damages (scored or out of round). Measure the cylinder bore in several places. If the measurement difference is more than .001 in. (0.03 mm) or taper is more than .002 (0.05 mm), the cylinder bore must be made larger (rebored or honed oversize). See SPECIFICATIONS.3. Install seal rings (3) in both ends of the crankcase housing.4. Install the new (unloader) pistons in their bore.
Be careful not to cause damage to the O-ring seals or the spiral rings.
5. Put the unloader plungers in their guides. Install the plunger and guide as a unit (6) to the crankcase housing and on top of the pistons. Install the unloader spring seat in the crankcase housing.6. Put saddle (4) in position between the unloader piston guides. Install (unloader) spring (8). Make sure it makes a seat on the spring seats and on the saddle.