821780T 1 Mercury COVER, Mount

Table 1
Required Tools
Tool Part Number Part Description Qty
B - Guide Studs
M16 by 115mm 2
C 8T-3052 Degree Wheel 1
D 1U-6396 Rubber Grease 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that wiring harness are correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.
Thoroughly clean the gasket surfaces of the cylinder head and the cylinder block. Do not damage the gasket surfaces of the cylinder head or the cylinder block. Ensure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.
Inspect the gasket surface of the cylinder head for distortion. Refer to Specifications, "Cylinder Head" for more information. If the gasket surface of the cylinder head is distorted beyond maximum permitted limits, replace the cylinder head.
Illustration 1 g02216033
Inspect dowels (31) for damage. If necessary, replace the dowels in the cylinder block.
Align a new cylinder head gasket (32) with dowels (31). Install the new cylinder head gasket (32) onto the cylinder block.
Install Tooling (B) to the cylinder block.
Use a suitable lifting device to lift cylinder head. The weight of the cylinder head is approximately 96 kg (212 lb).Note: A spreader bar must be used to distribute the weight of the cylinder head during the lifting operation.
Use Tooling (B) to align the cylinder head with the cylinder block. Install the cylinder head to the cylinder block.Note: Ensure that the cylinder head is correctly positioned on dowels (31).
Remove Tooling (B).
Illustration 2 g02216034
Clean bolts (29). Follow Step 9a for the procedure to inspect the bolts.
Use a straight edge to check the threads of the bolts. Refer to Illustration 2. Replace any bolts that show visual reduction in the diameter of the thread over Length (Y).
Lubricate the threads and the shoulder of bolts (29) with clean engine oil.
Illustration 3 g02206215
Illustration 4 g03417152
Install bolts (29) to cylinder head (30).
Tighten the bolts to a torque of 50 N m (37 lb ft) in the numerical sequence that is shown in Illustration 4.
Tighten the bolts to a torque of 100 N m (74 lb ft) in the numerical sequence that is shown in Illustration 4.
Use Tooling (C) to turn the bolts through an additional 225 degrees in the numerical sequence that is shown in Illustration 4.
Illustration 5 g02206214
Use Tooling (D) to lubricate the O-ring seals. Install new O-ring seal (27) and O-ring seal (28) to bypass tube (25). Install the bypass tube in the cylinder head. Install bolts (24). Tighten the bolts to a torque of 9 N m (80 lb in).
Follow Step 16a through Step 16c to connect harness assembly (22) to coolant temperature sensor (23).
Connect harness assembly (22) to coolant temperature sensor (23).
Slide locking tab (21) into the locked position.
Position harness assembly (22) onto the bypass tube and install a new cable strap (26).
Illustration 6 g02206213
Remove the plugs and caps from the ports and tube assembly.
Use Tooling (C) to lubricate new O-ring seals (17) (not shown). Install the O-ring seal to tube assembly (18) for the fuel return from the cylinder head.
Install tube assembly (18) to the cylinder head.
Install bolt (16) finger tight.
Install bolt (20) to tube clip (19) finger tight.
Tighten bolt (16) and bolt (20) to a torque of 22 N m (195 lb in).
Illustration 7 g02206194
Follow Step 23a through Step 23b to connect harness assembly (11) to inlet air temperature sensor (10).
Connect harness assembly (11) to inlet air temperature sensor (10).
Slide locking tab (12) into the locked position.
Follow Step 24a through Step 24b to connect harness assembly (15) to boost pressure sensor (13).
Connect harness assembly (15) to boost pressure sensor (13).
Slide locking tab (14) into the locked position.
Position the harness assembly onto the cylinder head. Use new cable straps to secure the harness assembly to the cylinder head. Ensure that the harness assembly is not strained.Note: Ensure that the harness assembly is clear of other engine components.
On some applications there is an engine wiring harness suppo