1135 Mercury COVER

2. Disconnect two lines (3). Remove two bolts (2) and water lines (1) as a unit. 3. Remove two bolts (7) at the bracket.4. Remove bolts (4) and (6) and remove water lines (5) as a unit. 5. Remove two bolts (12) and two bolts, washer and spacer (13). Remove two bolts and retainers (8) and (9) and remove tube assemblies (10) and (11). 6. Remove three bolts and washers (17) at the accumulator and the coolant conditioner mounting bracket (16). Move the bracket (16) and the dryer and coolant conditioner as a unit and reposition out of the way.7. Remove two bolts and washers (14) and oil filter mounting bracket (15). 8. Install Tooling (A) and a lift strap. 9. Disconnect the wires from the alternator.10. Remove five nuts (18) from bracket (19).11. Remove the oil filter and alternator and their mounting brackets as a unit. The weight of the unit is 57 kg (125 lb). 12. Remove O-ring (20) from bracket (19) and replace if necessary. 13. Install Tooling (A) as shown. Remove one nut (21) on rear of the gear cover and one on the front of the gear cover.14. Remove ten bolts (22) and pump gear cover (23). The weight and the pump gear cover (23) is 23.013 kg (50 lb). 15. Remove three bolts (28) and temperature regulator housing (27). Remove three bolts (26) and temperature regulator housing (25) and position out of the way.16. Remove spacer plate (24). 17. Put an identification mark on the gear for installation. Remove four 12 point bolts and retainer (29) and governor and fuel injection pump drive gear (30). 18. Remove retainer spring (31) and gear (32). 19. Disassemble flange assembly (33). 20. Remove outer spring (38), middle spring (37), inner spring (36), slide (35) and advance weight (34) from each side of flange assembly (33). 21. Remove two bolts (39) and elbow (40).22. Remove bolt and washer (41).23. Remove bolt and washer (42) and the wiring bracket. 24. Remove remaining bolts (43) and timing gear cover (44). 25. Check O-ring (45) at the fuel injection pump and replace if necessary.26. Remove timing gear cover gasket (46). The following steps are for the installation of the Timing Gear Cover & Governor & Fuel Injection Pump Drive Gear. 27. Check O-ring (45) at the fuel injection pump and replace if necessary.28. Install new timing gear cover gasket (46). 29. Install bolts (43) and timing gear cover (44). 30. Install bolt and washer (42) and the wiring bracket.31. Install bolt and washer (41).32. Install new gasket on elbow (40), two bolts (39) and elbow (40). 33. Assemble flange assembly (33). 34. Install outer spring (38), middle spring (37), inner spring (36), slide (35) and advance weight (34) on each side of flange assembly (33). Be sure the dowels in gear (32) are positioned in the stops when reassembling.35. Install retainer spring (31) and gear (32). 36. Use identification mark on the gear for installation. Install four 12 point bolts and retainer (29) and governor and fuel injection pump drive gear (30). Remove excessive oil, fuel and water from front face of timing gear housing, both faces of plate and mounting face of fuel pump gear cover with 6V-5765 Sealant. Apply as a continuous bead inside of hole pattern.37. Install three bolts (28) and temperature regulator housing (27). Install three bolts (26) and temperature regulator housing (25).38. Install spacer plate (24). Remove excessive oil, fuel and water from front face of timing gear housing, both faces of plate and mounting face of fuel pump gear cover with 6V-5765 Sealant. Apply as a continuous bead inside of hole pattern.39. Install Tooling (A) as shown. Install one nut (21) on rear of the gear cover and one on the front of the gear cover.40. Install ten bolts (22) and pump gear cover (23). The weight and the pump gear cover (23) is 23.013 kg (50 lb). 41. Install O-ring (20) on bracket (19). 42. Connect the wires to the alternator.43. Install five nuts (18) on bracket (19). Tighten nuts (18) to the torque of 25 5 N m (20 4 lb ft)44. Install the oil filter and alternator and their mounting brackets as a unit. The weight of the unit is 57 kg (125 lb). 45. Install Tooling (A) and a lift strap. 46. Install three bolts and washers (15) at the dryer and the coolant conditioner mounting bracket, and dryer. Install the bracket and the dryer and coolant conditioner.47. Install two bolts and washers (14) and oil filter mounting bracket (15). 48. Install two bolts (12) and two bolts, washer and spacer (13). Install two bolts and retainers (8) and (9) and install tube assemblies (10) and (11).49. Check the gaskets at the cylinder block and and the O-rings at the oil filter connection and replace if necessary. 50. Install two bolts (7) and the bracket.51. Install bolts (4) and (6) and install water lines (5) as a unit.52. Install new gaskets at the regulator housings and check all O-rings. 53. Connect two lines (3). Install two bolts (2) and water lines (1) as a unit.54. Install new gasket at the water pump and regulator housing.55. Install the four bolts and washers at the air conditioner compressor mounting bracket.End By:a. install crankshaft front seal and wear sleeveb. install engine front support and trunnionc. install water pumpd. install vibration damper and crankshaft pulleye. install oil panf. install fan driveg. install fan assembly