808528 Mercruiser ROTOR

START BY:a. remove exhaust manifoldb. remove rocker shaft assembly and push rodsc. remove air cleaner groupd. remove aftercooler 1. Remove bolts (1) and the clips that hold wiring harness (3) to support (2).2. Fasten a hoist to the support. Remove the bolts that hold the support to the engine and transmission support. Remove support (2). Weight is 41 kg (90 lb.). 3. Loosen bolt (4) to remove tension on the fan belts. 4. Remove radiator pipe (5) from the radiator and cylinder head.5. Disconnect wiring (6) from the temperature sending unit in the top of the cylinder head.6. Disconnect wiring (7) from the temperature sending unit in the side of the head.7. Remove bolt and bracket (8) from the cylinder head. 8. Fasten a hoist to the fan drive. Remove four bolts (9) and use a piece of wire to hold the fan drive up.
Do not let the fan damage the radiator core.
Typical Example9. Install tooling (A) on the cylinder head assembly as shown, and fasten a hoist on it.
Do not set the cylinder head assembly on a flat surface or possible damage to the fuel injection nozzle tips will be caused.
10. Remove all bolts (11) that hold the cylinder head assembly (10) to the cylinder block. Remove the cylinder head assembly. Weight is 95 kg (210 lb.). 11. Remove head gasket (12), water seals (14) and the O-ring seal from dowel (13). Remove spacer plate (15), the spacer plate gasket and the O-ring seal from dowel (13).Install Cylinder Head Assembly And Spacer Plate
When the cylinder head assembly is removed, a new spacer plate gasket and a new cylinder head gasket must be installed. Do not use any adhesive or other substances on these gaskets or the surfaces they contact.
Typical Example1. Thoroughly clean the spacer plate cylinder head and cylinder block surfaces. If dowel (1) was removed for any reason, install a new dowel until it extends 16.0 0.5 mm (.63 .02 in.) from the cylinder block.2. Install the O-ring seal on dowel (1) against the cylinder block. Install spacer plate gasket (2) and spacer plate (3) on the cylinder block.3. Check the cylinder liner projection height. See the topic, Install Cylinder Lines.
Typical Example4. Install the O-ring seal on top of the spacer plate around dowel (1). Instal cylinder head gasket (4) and water seals (5). 5. Install tooling (A) on the cylinder head assembly as shown, and fasten a hoist to it. Put the cylinder head assembly in position on the engine.6. Put 2P2506 Thread Lubricant on all the cylinder head bolts, and install them until they are finger tight. Remove tooling (A) from the cylinder head. 7. Install push rods (6). Make sure they are installed in their original locations. Be sure the push rods are in position in the valve lifters.8. Loosen the adjusting screws on the rocker arms for valve clearance. This will prevent a bent valve or push rod during installation of the rocker shaft assembly.9. Install a new O-ring seal in the rear rocker arm support bracket.10. Put 2P2506 Thread Lubricant on all of the rocker shaft bolts, except the one that goes through the rear rocker arm support bracket.11. Put rocker shaft assembly (7) in position on the cylinder head assembly. Make sure the dowels in the support brackets are in the dowel holes in the cylinder head assembly and the rocker arms are engaged with the push rods. Install the bolts that hold the rocker shaft assembly until they are finger tight. 12. Hand tighten the large size cylinder head and rocker shaft bolts in the numbered sequence shown for each engine as follows:a. Tighten the bolts in the numbered sequence to a torque of 156 N m (115 lb. ft.).b. Tighten the bolts in the numbered sequence to a torque of 250 17 N m (185 13 lb. ft.).c. Tighten the bolts in the numbered sequence again to a torque of 250 17 N m (185 13 lb. ft.).13. Hand tighten the small size cylinder head bolts, in the lettered sequence shown for each engine to a torque of 43 7 N m (32 5 lb. ft.).14. See Topic, Valve Clearance in Testing And Adjusting, and make an adjustment to the valves. The intake valves must have a clearance of 0.38 mm (.015 in.). The exhaust valves must have a clearance of 0.64 mm (.025 in.). 15. Fasten a hoist to the fan drive and put it in position on the front of the cylinder head. Install four bolts (8). 16. Install bracket and bolt (12) on the cylinder head.17. Connect wiring (11) to the temperature sending unit in the side of the head.18. Connect wiring (10) to the temperature sending unit in the top of the head.19. Install radiator pipe (9) on the radiator and cylinder head. 20. Tighten bolt (13) and then see FAN BELT TENSION CHART in SPECIFICATIONS. 21. Put support (14) in position on the engine and transmission support with the bolts that hold it.22. Put wiring harness (15) in position and install bolts (16) that hold it.END BY:a. install aftercoolerb. install air cleaner groupc. install exhaust manifold