78529 Mercury COVER, EXHAUST MANIFOLD

Table 1
Required Tools
Tool Part Number Part Description Qty
A 230-6284 Timing Pin (Camshaft) 1
B 230-6283 Timing Pin (Crankshaft) 1 Start By:
If the engine is equipped with an air compressor, remove the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove and Install".
If the engine is equipped with a vacuum pump, remove the vacuum pump. Refer to Disassembly and Assembly, "Vacuum Pump - Remove and Install".
If the engine is equipped with an accessory drive, remove the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive - Remove and Install".
Remove the fuel injection pump gear. Refer to Disassembly and Assembly, "Fuel Pump Gear - Remove".
Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install". Note: Care must be taken in order to ensure that the fuel injection pump timing is not lost during the removal of the fuel pump gear. Carefully follow the procedure in order to remove the fuel pump gear.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01343975
Alignment of timing marks
Ensure that Tooling (A) is installed into hole (X) in the camshaft gear. Use Tooling (A) in order to lock the camshaft in the correct position. Note: Ensure that the gears are marked in order to show alignment. Refer to Illustration 1.
Ensure that Tooling (B) is installed in hole (Y) in the front housing. Use Tooling (B) in order to lock the crankshaft in the correct position.
Illustration 2 g01348926
Typical example
Loosen nuts (4) on all rocker arms (5). Unscrew adjusters (3) on all rocker arms (5) until all valves are fully closed. Note: Failure to ensure that ALL adjusters are fully unscrewed can result in contact between the valves and pistons.
Mark plate (3) in order to show orientation. Refer to Illustration 1. Note: Identification will ensure that the plate can be installed in the original orientation.
Remove bolts (1). Refer to Illustration 1.
Remove plate (3).
Illustration 3 g01269930
Typical example
Remove the assembly of idler gear (2) and hub (7) from the recess in the front housing. Note: The idler gear must be tilted during removal.
Remove hub (7) from idler gear (2). Removal Procedure (Heavy-Duty Idler Gear)
Table 2
Required Tools
Tool Part Number Part Description Qty
A 230-6284 Timing Pin (Camshaft) 1
B 230-6283 Timing Pin (Crankshaft) 1
C - Bolt
(M8x80mm) 1 Start By:
If the engine is equipped with an air compressor, remove the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove and Install".
If the engine is equipped with a vacuum pump, remove the vacuum pump. Refer to Disassembly and Assembly, "Vacuum Pump - Remove and Install".
If the engine is equipped with an accessory drive, remove the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive - Remove and Install".
Remove the fuel injection pump gear. Refer to Disassembly and Assembly, "Fuel Pump Gear - Remove".
Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install". Note: Care must be taken in order to ensure that the fuel injection pump timing is not lost during the removal of the fuel pump gear. Carefully follow the procedure in order to remove the fuel pump gear.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: The assembly of heavy-duty idler gear is not serviceable. Do not disassemble the heavy-duty idler gear.
Illustration 4 g01343977
Alignment of timing marks
Ensure that Tooling (A) is installed into hole (X) in the camshaft gear. Use Tooling (A) in order to lock the camshaft in the correct position. Note: Ensure that the gears are marked in order to show alignment. Refer to Illustration 4.
Ensure that Tooling (B) is installed in hole (Y) in the front housing. Use Tooling (B) in order to lock the crankshaft in the correct position.
Illustration 5 g01348930
Typical example
Loosen n