809163 Mercruiser REGULATOR ASSEMBLY

Illustration 1 g00123062
Front view of cylinder block
Illustration 2 g00123064 (1) Spacer plate Thickness of spacer plates ... 12.313 mm (0.4848 inch) (2) Gasket Thickness of gasket between the cylinder block and spacer plates ... 0.18 to 0.22 mm (0.007 to 0.009 inch) (3) Dowel All dowels extend above the face by the following distance: ... 21.0 0.5 mm (0.83 0.02 inch) (4) Plug Torque ... 100 15 N m (75 11 lb ft) (5) Height of Cylinder liner For the correct method of determining height of the liner, refer to Testing And Adjusting, "Cylinder Liner Projection". (6) Bore Bore in the block for the camshaft bearings ... 98.000 0.020 mm (3.8583 0.0008 inch) (7) Camshaft bearing junction (8) Centerline through oil holes in camshaft bearings Oil holes must be positioned from horizontal at angle (X) to the following angle: ... 20 5 degreesNote: All centerlines through oil holes in the camshaft bearings (8) and bearing junctions (7) must be in the position that is shown for each side of the cylinder block. (9) New dimension from centerline of crankshaft bearing bore to the top of the block ... 586.00 mm (23.071 inch) (10) Main bearing cap width Width of main bearing cap ... 340.030 0.015 mm (13.3870 0.0006 inch)Width of cylinder block for main bearing cap ... 339.985 0.015 mm (13.3852 0.0006 inch)Tight press fit between the sides of the main bearing cap and the cylinder block ... 0.075 mm (0.0030 inch)Loose press fit between the sides of the main bearing cap and the cylinder block ... 0.015 mm (0.0006 inch) (11) Bore in the block for the main bearings Standard, original new size ... 169.742 0.020 mm (6.6827 0.0008 inch) 0.63 mm (0.025 inch) larger than original size ... 170.372 0.020 mm (6.7076 0.0008 inch) (12) New dimension from the centerline of the crankshaft bearing bore to the bottom of the block (pan rails) ... 230.00 mm (9.055 inch) (13) Main bearing cap bolts Install main bearing caps with the part number and FRONT toward the front of the block. Each cap has a number. Each cap must be installed in the same position as the correct number on the side of the cylinder block pan rail.Note: The procedure to tighten the main bearing cap bolts depends on the diameter of the bolts. There is a different procedure for 3/4 inch bolts and for 7/8 inch bolts.Procedure for Tightening 3/4 Inch Diameter Bolts ( 5P-8288 Bolt)
Put clean engine oil on the bolts before assembly.
Tighten the bolts in the letter sequence. Torque ... 136 14 N m (100 10 lb ft)
Tighten the bolts in the letter sequence again. Rotation ... 210 5 degreesProcedure for Tightening 7/8 Inch Diameter Bolts ( 7X-7925 Bolt)
Put clean engine oil on the bolts before assembly.
Tighten the bolts in the letter sequence. Torque ... 190 14 N m (140 10 lb ft)
Tighten the bolts in the letter sequence again. Rotation ... 180 5 degrees (14) Dowel The dowel extends from the rear face of the block by the following distance: ... 6.0 0.5 mm (0.24 0.02 inch) (15) Plug Torque ... 100 15 N m (75 11 lb ft) (16) Dowel The dowels extend from the front face of the block by the following distance: ... 6.0 0.5 mm (0.24 0.02 inch) (17) Dowel The dowels extend from the rear face of the block by the following distance: ... 19.0 0.5 mm (0.75 0.02 inch) (18) Dowel The dowels extend from the front face of the block by the following distance: ... 40.0 0.5 mm (1.58 0.02 inch)