853804 Mercury CONNECTOR SHIFT KIT

Start By:a. remove exhaust manifoldb. remove valve cover1. Drain the coolant from the cooling system. 2. Remove the four bolts, gasket and elbow (1) from the cylinder head assembly. 3. Loosen bolts (3) and remove v-belt (2) from the belt tightener. 4. Remove bolts (5), (10) and (11), and remove oil filler tube (4) from the engine.5. Loosen the hose clamp, and remove hose (7) from the elbow.6. Remove the bolt and clip (8) that holds hose (7) to the cylinder head assembly.7. Remove bolt (6) that holds the dipstick tube assembly to the cylinder head assembly.8. Loosen hose clamp (9). 9. Remove bolts (12), (14) and (15), and remove the gaskets and elbow (13) from the water pump, cylinder head assembly and hose (16).10. Remove the water temperature regulator. See the topic, Remove Water Temperature Regulator, in this module. 11. Attach a nylon strap and hoist around the air conditioning compressor and bracket (17). Remove the four bolts, and set the air conditioning compressor on the side of the tractor, (do not disconnect hoses).12. Mark and remove two wires (19), two wires (21) and wire (22).13. Disconnect wire harness (18).14. Disconnect line (20) from the air filter service indicator. 15. Loosen bolts (23) and (25), and release the tension on v-belts (24). 16. Install a nylon strap and hoist to support fan and fan drive assembly (26) as shown. Remove the four bolts that hold the fan drive to the cylinder head assembly. Rest the fan against the radiator cores and on the lower fan guards.
Care must be taken when unbolting the fan drive and also when positioning the fan against the radiator, that no damage to the radiator occurs.
17. Remove the rocker shaft and push rods. See the topic, Remove Rocker Shaft And Push Rods in this module. 18. Remove all bolts (28) and (29) that hold the cylinder head assembly to the cylinder block.19. Install tooling (A) and a hoist on cylinder head assembly (27), and remove the cylinder head assembly from the engine. The weight of the cylinder head assembly is approximately 68 Kg (150 lb).20. Remove the spacer plate. See the topic, Remove Spacer Plate in this module.Install Cylinder Head Assembly
1. Install the spacer plate. See the topic, Install Spacer Plate in this module. 2. Install tooling (A) on the cylinder head assembly, and fasten a hoist to it. Put the cylinder head assembly in position on the engine.3. Put 2P2506 Thread Lubricant on all cylinder head bolts (28) and (29), and install them until they are finger tight. Remove tooling (A) from the engine. 4. Install push rods (33). Make sure they are installed in their original locations. Be sure the push rods are in position in the valve lifters.5. 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,6. Install a new O-ring seal in the rear rocker arm support bracket.7. Put 2P2506 Thread Lubricant on all of the rocker shaft bolts except the one that goes through the rear rocker arm support bracket.8. Put rocker shaft assembly (30) 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. 9. Hand tighten the large size cylinder head and rocker shaft bolts in the numbered sequence shown 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).10. Hand tighten the small size cylinder head bolts, in the lettered sequence shown to a torque of 43 7 N m (32 5 lb ft).11. The assembled length of springs (32) at both ends of the rocker shaft assembly must be 1.50 0.25 mm (.059 .010 in). Remove or install the washers behind the springs to obtain the correct assembled length of the springs.12. Make an adjustment to the valves until the intake valve clearance is 0.38 mm (.015 in) and the exhaust valve clearance is 0.64 mm (.025 in). Tighten the nuts on adjustment screws (31) to a torque of 29 7 N m (21 5 lb ft). For the complete valve adjustment procedure, see Valve Clearance in Testing And Adjusting. 13. Use a nylon strap and hoist to position fan and fan drive assembly (26) on the engine, and install the four bolts that hold it in place.
Care must be taken when lifting the fan and fan drive assembly away from the radiator so that the radiator is not damaged.
14. Position the v-belts on the fan drive pulley. 15. Position v-belts (24) on the alternator pulley.16. Use a belt tension gauge such as a Burroughs BT-33-72 C gauge to check the belt tension. Adjust a new belt set to a gauge reading of 534 22 N (120 5 lb). Adjust a used belt set to a gauge reading of 400 44 N (90 10 lb). Tighten bolts (23) and (25). 17. Connect wire harness (18).18. Connect line (20) to the air filter service indicator.19. Connect two wires (19), two wires (21) and wire (22).20. Use a nylon strap and hoist to position the air conditioning compressor and bracket (17) on the cylinder head assembly. Install the four bolts that hold it in place. 21. Install the water temperature regulator. See the topic, Install Water Temperature Regulator, in this module.22. Install the gaskets and elbow (13) on the water pump, cylinder head assembly and hose (16). Install bolts (12), (14) and (15) that hold the elbow