864378 Mercruiser SCREW, (.250-20 x .375) Torx

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Guide Studs
(M16 by 115mm) 2
B 8T-3052 Angle gauge 1
C 1U-6396 O-Ring Assembly Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Thoroughly clean the gasket surfaces of the cylinder head and the cylinder block. Do not damage the gasket surfaces of the cylinder head of the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.
Inspect the gasket surface of the cylinder head for distortion. Refer to Specifications, "Cylinder Head" for more information. If the gasket surface of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head.
If necessary, install the inlet manifold to the cylinder head. Refer to Disassembly and Assembly, "Inlet manifold - Remove and Install" for the correct procedure.
Illustration 1 g03370339
Inspect dowels (27) for damage. If necessary, replace the dowels in the cylinder block.
Install Tooling (A) to the cylinder block.
Align cylinder head gasket (28) with dowels (27). Install cylinder head gasket (28) onto the cylinder block.
Illustration 2 g03369770
Use a suitable lifting device (26) to lift cylinder head (25). The weight of the cylinder head is approximately 66 kg (145.5 lb).Note: A spreader bar must be used to distribute the weight of the cylinder head during the lifting operation.
Use Tooling (A) to align cylinder head (18) with the cylinder block. Install the cylinder head to the cylinder block.Note: Ensure that the cylinder head is correctly positioned on dowels.
Remove Tooling (A).
Illustration 3 g03370340
Clean bolts (24). Follow Steps 10.a for the procedure to inspect the bolts.
Use a straight edge to check the threads of the bolts. Refer to Illustration 3. Replace any bolts that show visual reduction in the diameter of the thread over Length (Y).
Lubricate the threads and the shoulder of bolts (24) with clean engine oil.
Illustration 4 g03369768
Illustration 5 g06239253
Install bolts (24) to cylinder head (25).
Tighten the bolts to a torque of 50 N m (37 lb ft) in the numerical sequence. Refer to Illustration 5.
Tighten the bolts to a torque of 100 N m (74 lb ft) in the numerical sequence. Refer to Illustration 5.
Turn the bolts through an extra 225 degrees in the numerical sequence. Refer to Illustration 5. Use Tooling (B) to achieve the correct final torque.
Illustration 6 g03369767
Use Tooling (C) to lubricate the O-ring seals. Install new O-ring seal (23) and new O-ring seal (22) to bypass tube (21). Install the bypass tube in the cylinder head. Install bolts (20). Tighten the bolts to a torque of 22 N m (16 lb ft).
Illustration 7 g03369766
Install a new O-ring seal (17) (not shown) to tube assembly (19).
Connect tube assembly (18) to the cylinder head. Ensure that the tube assembly is correctly seated into the cylinder head.
Install bolt (14) and bolt (19) to tube assembly (18). Tighten the bolts to a torque of 22 N m (195 lb in).
Follow Step 20.a through Step 20.c to connect tube assembly (16).
Install a new sealing washer (11) (not shown) to banjo bolt (10).
Install banjo bolt (10) to tube assembly (16).
Install the remaining new sealing washer (11) (not shown) to banjo bolt (10).Tighten banjo bolt (10). Tighten the banjo bolt to a torque of 15 N m (133 lb in).
Install bolt (15) to tube assembly (16). Tighten the bolt to a torque of 44 N m (32 lb ft).
Connect harness assembly (12) to wastegate solenoid (13).
Illustration 8 g03369783
Illustration 9 g03369782