801331602 Mercruiser EXPANSION PLUG

1. Remove front lifting plate (1) from the front of the cylinder head.2. Loosen the tension on the vee belts for the fan drive and alternator. 3. Fasten a hoist to the fan and fan drive. Remove the four bolts that hold fan drive (2) to the front of the cylinder head.
Make sure the fan does not cause damage to the radiator core when the fan drive is fastened to tool (A).
4. Install tool (A) as shown. Use tool (A) as a support for the fan and fan drive.5. Remove temperature sensing unit (3) from the cylinder head.6. Remove two bolts (5) that hold the transmission oil filter bracket to the cylinder head.7. Remove two bolts (4) that hold the water pump elbow to the cylinder head and loosen the bolts to hold the water pump to the engine. 8. Remove oil tube assemblies (7) and (9) from the turbocharger and the engine.9. Remove bracket (6) from the cylinder head and hydraulic tank.10. Remove clip (8) from the cylinder head. 11. Fasten a hoist to cylinder head (11) with tooling (B). Remove bolts (10) and remove cylinder head (11) from the engine. The weight of the cylinder head is 206 Kg (455 lb.). 12. Remove head gasket (12), water seals (13) and O-ring seal (14) from the engine block. Any time the cylinder head is removed a new spacer plate gasket must be installed. See the topic, REMOVE SPACER PLATE.Install Cylinder Head
Any time the cylinder head is removed a new spacer plate gasket must be installed. See the topic, INSTALL SPACER PLATE. 1. Thoroughly clean the spacer plate and the bottom surface of the cylinder head. Install a new head gasket (3), water seals (1) and O-ring seal (2). 2. Fasten a hoist to cylinder head (4) with tooling (A) and put the cylinder head in position. 3. Install the push rods and put rocker shaft (5) in position on the cylinder head. See the topic, INSTALL ROCKER SHAFT AND PUSH RODS.4. Put 5P3931 Anti-Seize Compound on the threads of the cylinder head and rocker shaft bolts. Install the bolts and tighten these as follows:a. Tighten all the bolts in number sequence to a torque of 155 N m (115 lb.ft.).b. Tighten all bolts in number sequence to a torque of 250 17 N m (185 13 lb.ft.).c. Tighten all bolts in number sequence (hand turn only) to a torque of 250 17 N m (185 13 lb.ft.).d. Tighten all bolts in letter sequence to a torque of 30 N m (22 lb.ft.).e. Tighten all bolts in letter sequence to a torque of 43 7 N m (32 5 lb.ft.).f. Tighten all bolts in letter sequence (hand turn only) to a torque of 43 7 N m (32 5 lb.ft.).5. Make adjustments until the intake valve clearance is 0.38 mm (.015 in.) and the exhaust valve clearance is 0.64 mm (.025 in.). See VALVE CLEARANCE SETTING in TESTING AND ADJUSTING. 6. Install clip (7) to hold wire harness to the cylinder head. 7. Install bracket (6) between the hydraulic tank and cylinder head.8. Install oil tube assemblies (8) and (9) on the turbocharger and engine. 9. Make sure the gasket for water pump elbow (13) is in position and install the two bolts that hold it to the cylinder head. Tighten the bolts that hold the water pump to the engine.10. Install bolts (12) that hold the transmission oil filter bracket to the cylinder head.11. Install water temperature sensing unit (11) in the cylinder head.12. Fasten a hoist to the fan drive and remove it from tool (A). Remove tool (A) from the front of the cylinder block and fasten the fan drive to the cylinder head. Make an adjustment to the vee belt tension. See ENGINE SPECIFICATIONS for the correct tension on the vee belts.13. Install lifting plate (10) on the front of the cylinder head.End By:a. install water temperature regulator