807757T Mercruiser PULLEY

start by: a) remove rocker shaft and push rodsb) remove fuel injection lines1. Drain the coolant from the cooling system. 2. Remove two bolts (6) from the top of the water pump.3. Remove water temperature sensing bulb (3) from the cylinder head.4. Disconnect the oil level tube (4) and oil filler tube (2) from the cylinder head.5. Disconnect heater hose (5).6. Loosen one clamp, remove two bolts and remove hose and elbow (1) that is fastened to the radiator. Disconnect two clamps that hold the breather tube to the timing gear housing.7. Loosen the tension in the vee belts for the fan and alternator.8. Fasten a hoist to the fan and fan drive. Remove the four bolts that hold the fan drive to the cylinder head. Move the fan and fan drive toward the radiator core. 9. Install tool (A) in front of the cylinder block as shown. Fasten the fan drive to tool (A). Tool (A) will hold the fan and fan drive up when the cylinder head is removed. 10. Remove the inlet tube assembly (7) and the return tube assembly (8) from the turbocharger and cylinder block.11. Disconnect two clips (9) that hold the fuel pressure tube to the cylinder head. 12. Remove the thirty-three bolts (10) that hold the cylinder head to the cylinder block. 13. Fasten a hoist to the eyebolts in the cylinder head. Fasten tool (B) to the turbocharger and the hoist. Remove the cylinder head assembly (11). The weight of the cylinder head assembly is 350 lb. (159 kg).14. Remove the cylinder head gasket.Install Cylinder Head Assembly
1. Clean the machine surfaces of the cylinder head and cylinder block that make contact with the cylinder head gasket. 2. Put a new cylinder head gasket (2) in position on the cylinder block. Make sure the holes in the cylinder head gasket are in alignment with the holes in the cylinder block. Fasten a hoist to the eyebolts in the cylinder head. Fasten tool (B) to the turbocharger and the hoist. Put the cylinder head (1) in position on the cylinder block. 3. Install push rods (3). Put rocker shaft (4) in position on the cylinder head.
Make sure the dowels in the rocker shaft assembly are in alignment with the holes in the cylinder head before the bolts are installed and tightened.
4. Put 9M3710 Anti-Seize Compound on the threads of the cylinder head bolts and rocker shaft bolts. Install the bolts and washers and tighten the bolts as follows: a) Tighten all the bolts in number sequence to a torque of 115 lb.ft. (155 N m).b) Tighten all bolts in number sequence to a torque of 175 5 lb.ft. (240 7 N m).c) Tighten all bolts in number sequence (hand turn only) to a torque of 175 5 lb.ft. (240 7 N m). The minimum amount of torque on these bolts after the engine is warm must be 150 lb.ft. (205 N m).d) Tighten all bolts in letter sequence to a torque of 22 lb.ft. (28 N m).e) Tighten all bolts in letter sequence to a torque of 32 5 lb.ft. (43 7 N m).f) Tighten all bolts in letter sequence (hand turn only) to a torque of 32 5 lb.ft. (43 7 N m). The minimum amount of torque on these bolts must be 27 lb.ft. (38 N m) after the engine is warm. 5. Make adjustments until the intake valve clearance is .015 in. (0.38 mm) and the exhaust valve clearance is .025 in. (0.64 mm). See VALVE CLEARANCE SETTING in TESTING AND ADJUSTING. 6. Install the valve cover (5). See INSTALL VALVE COVER. 7. 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 FAN AND ALTERNATOR BELTS in LUBRICATION AND MAINTENANCE GUIDE. 8. Connect the two clips (8) that hold the fuel pressure tube to the cylinder head. Install the inlet tube (6) and return tube (7) to the turbocharger and cylinder block.9. Connect the clamps that hold the breather tube to the timing gear cover. 10. Install the breather cap (10).11. Put hose and elbow (9) in position. Install two bolts and tighten clamp to hold it.12. Install the two bolts that hold the housing for the water pump to the cylinder head. 13. Install the water temperature sensing bulb (14) to the cylinder head.14. Connect oil level tube (12) and oil filler tube (13) to the cylinder head.15. Connect heater hose (15) to cylinder head and install glow plug wire harness (11). 16. Remove tool (C) and install the electric starting motor. See INSTALL ELECTRIC STARTING MOTOR.17. Fill the cooling system with coolant to the correct level. See LUBRICATION AND MAINTENANCE GUIDE.end by:a) install fuel injection linesb) install air cleaner assembly