809142 Mercruiser TERMINAL

2. Remove air compressor outlet hose (1).3. Remove air compressor air inlet tube (3).4. Remove air compressor coolant outlet tube (4).5. Remove turbocharger oil return tube (2). 6. Use tooling (A) to remove studs (5).7. Turn the flywheel with tool (B), and remove each bolt (6) as it becomes accessible.8. Turn the flywheel with tool (B) until the "V" marks on the front timing gears in alignment.9. Install tooling (C) through the holes for studs (5) into camshaft rear gear (7).
Tooling (C) must be used to prevent the loss of rear balance weight timing and to keep the camshaft rear gear in place when the camshaft is removed.
10. Tighten tooling (C) evenly to remove the camshaft rear gear from the camshaft. 11. Remove thrust plate (8).12. Carefully remove camshaft and gear (9) from the cylinder block.
Be careful not to damage the camshaft bearings. Do not pry the camshaft out of the cylinder block. If resistance to camshaft removal occurs, turn the camshaft so the lobes will align the bearing journals with the camshaft bearing bores.
13. If removal of the camshaft gear is necessary, place the camshaft and gear in a hydraulic press. Place tool (D) over the camshaft, and press against it to remove the camshaft from the gear.
Be careful not to scratch or damage the finished surfaces of the camshaft.
14. Remove the key from the camshaft.15. If dowel removal is necessary, use tool (E) to remove the dowel.Install Camshaft
1. Install the key in the camshaft. Be sure the key is seated in the camshaft.2. Install the pin in the rear of the camshaft. Install the pin to a height of 8.51 to 9.01 mm (.335 to .355 in.).3. Heat the camshaft drive gear to a maximum temperature of 316°C (600°F), align the groove in the drive gear with the key in the camshaft and install the camshaft drive gear with the timing marks away from the camshaft.4. Put 2P2506 Thread Lubricant on the lobes of the camshaft. Put clean engine oil on the camshaft bearing journals.5. Carefully install the camshaft into the cylinder block. Do not force the camshaft into position. If resistance to camshaft installation occurs, turn the camshaft so the lobes will align the bearing journals with the camshaft bearing bores. 6. Align the "V" marks on the camshaft drive gear (2) and idler gear (3).7. Install thrust plate (1) to hold the camshaft and camshaft drive gear (2) in the cylinder block. 8. Loosen the bolts [tool (B)] that hold camshaft rear gear (5) so camshaft rear gear (5) will engage the dowel on the rear of the camshaft.9. After the dowel is engaged, remove tool (B), and install bolts (4).10. Use tool (A) to turn the flywheel, and install each of four bolts (4). Tighten bolts (4) to a torque of 13 to 17 N m (17 to 23 lb.ft.).11. Put 5P3413 Pipe Sealant on the threads of studs (6). Use tooling (C) to install the studs. 12. Install turbocharger oil return tube (9) with a new gasket and O-ring seal.13. Install air compressor coolant outlet tube (11).14. Install air compressor air inlet tube (10).15. Install air compressor outlet hose (8).END BY:a. install push rods and valve liftersb. install timing gear coverc. install radiator and guard