5447500NP Mercruiser STERNDRIVE UNIT, Complete

1. Remove bolts (1) that hold plate (2), and remove the plate. 2. Remove bolts (3) and (4) that hold the cylinder head assembly to the cylinder block.3. Fasten a hoist, and remove the cylinder head assembly. The weight is approximately 135 kg (297 lb).
Do not put the cylinder head assembly down on a flat surface. This can cause damage to the fuel injection valves.
4. Remove the gasket, seals (5) and O-ring seals (6) from the spacer plate. The following steps are for installation of the cylinder head. Be sure a new gasket has been installed between the spacer plate and the cylinder block. See the topic "Remove & Install Spacer Plate".5. Thoroughly clean the spacer plate and the bottom surface of the cylinder head assembly. Install a new head gasket, new seals (5) and two O-ring seals (6).6. Fasten a hoist, and put the cylinder head assembly in position on the cylinder block. 7. Put clean engine oil on the threads of the cylinder head bolts. Install the cylinder head bolts and washers. Tighten the bolts in sequence shown. a. Tighten bolts 1 through 14 in number sequence to a torque of 270 25 N m (200 18 lb ft).b. Tighten bolts 1 through 14 in number sequence to a torque of 470 20 N m (345 15 lb ft).c. Tighten bolts 1 through 14 in number sequence to a torque of 470 20 N m (345 15 lb ft) by hand.d. Install the rocker shaft assemblies and push rods. See the topic, "Install Rocker Shaft Assemblies And Push Rods".e. Tighten bolts 15 through 26 in number sequence to a torque of 270 25 N m (200 18 lb ft).f. Tighten bolts 15 through 26 in number sequence to a torque of 450 20 N m (330 15 lb ft).g. Tighten bolts 15 through 26 in number sequence to a torque of 450 20 N m (330 15 lb ft) by hand.h. Tighten the (3/8 in) bolts to a torque of 45 7 N m (33 5 lb ft) after the cylinder head bolts (3/4 in) bolts have been given the final torque. If the studs for the exhaust manifold were removed, install new studs, and tighten them to a torque of 35 5 N m (26 4 lb ft).8. Make an adjustment to the valves to have a clearance of 0.38 mm (.015 in) for inlet and 0.76 mm (.030 in) for exhaust. Tighten the locknuts for the valve adjustment screws to a torque of 28 4 N m (21 3 lb ft).9. Install the valve cover bases and the inner fuel lines. See the topic "Install Rocker Shaft Assemblies & Push Rods".10. Install the valve covers. See the topic "Install Valve Covers".11. Install plate (2).End By:a. install aftercooler housingb. install exhaust manifoldc. install fuel injection linesd. install water temperature regulatore. install rocker shaft assemblies and push rods