809162 Mercruiser RECTIFIER

Remove Air Compressor
START BY:a. remove turbochargerb. remove exhaust manifold and muffler 1. Remove three lines (1) to the air compressor.2. Disconnect line (2) and two hoses (3). 3. Remove three nuts and washers (5).4. Remove air compressor (4).Install Air Compressor
1. Install O-ring seal (2) on the air compressor, and install air compressor (1). Install three washers and nuts. 2. Connect line (4) and two hoses (5).3. Install three lines (3).END BY:a. install exhaust manifold and mufflerb. install turbochargerDisassemble Air Compressor
START BY:a. remove air compressorb. remove accessory drive 1. 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 (unloaded) 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.7. Install inlet valve guides (10) on (unloader) bore bushing (2) in the case housing. Put inlet valves (9) in the guides.8. Install strainer (7), the gasket and cover (5) over the air inlet port of the crankcase housing. Install the bolts that hold the cover. 9. Install bearing (11) in the cover with tooling (A). Make sure the groove in the bearing is in alignment with the oil hole in the cover. Install thrust washer (12) and O-ring seal (13).10. Put clean SAE 30 engine oil on the bearing and the seal. Install the end cover and the bolts that hold it to the crankcase housing.11. Install the crankcase in the crankcase housing and the end cover bearing. 12. Install the bearing in adapter with tooling (B). Install thrust washer (14) and O-ring seal (15) in the adapter.13. Put clean SAE 30 engine oil on the bearing and the O-ring seal. Install the adapter over the crankshaft and to the housing. Install the bolts that hold the adapter. Tighten the bolts to a torque of 38 to 45 lb.ft. (49 to 60 N m). 14. Assemble the piston rings on the piston with tooling (C) as follows:a. Check piston ring (16) gaps. Check with the piston rings in the cylinder bore. The gap clearance must be .002 to .010 in. (0.05 to 0.25 mm).b. Install expander ring (17) on the bottom