880703A 1 Mercury COVER ASSEMBLY

START BY:a. remove cylinder head assemblyb. remove oil pan 1. Put the engine in position on tooling (A) as shown. 2. Remove the carbon ridge from the top inside surface of the cylinders with tool (B). 3. Turn the crankshaft until the two center pistons are in the down position.4. Remove nuts (1) and rod cap (2). Put pieces of rubber hose on tape on the threads of the connecting rod bolts as protection for the crankshaft. 5. Push the piston and connecting rod away from the crankshaft until the piston rings are above the cylinder block.6. Remove piston (3) and connecting rod (4) as a unit. Keep each connecting rod cap with its respective connecting rod and piston.
Do not turn the crankshaft while any of the connecting rods are in the engine without the caps installed.
7. Repeat Steps 3 through 6 for the remainder of the pistons.Install Pistons And Connecting Rods
1. Put the engine in position on tooling (A).2. Put clean engine oil on the piston rings, connecting rod bearings, cylinder walls and crankshaft journals. 3. Make sure the piston ring gaps are at lease 120° apart on the piston.4. Use tool (B), and install the piston and connecting rod in the same cylinder bore of the engine from which it was removed. The hole (crater) in the top of the piston must be toward the camshaft side of the engine. For more detail concerning the installation of connecting rod bearings, see Remove And Install Connecting Rod Bearings.5. Check the bearing clearances with tool (C). For complete details concerning measuring bearing clearances, see Engine Bearing And Crankshafts, Form No. SEBD0531.6. Put clean engine oil on the threads of the bolts and contact surfaces of the nuts for the connecting rod caps.
When the connecting rod caps are installed, make sure that the number on the side of the cap (1) is next to and respective with the number on the side of the connecting rod (2).
7. Put the cap (1) in position on the connecting rod, and install the nuts. Tighten the nuts to a torque of 40 4 N m (30 3 lb.ft.). Put a mark on each nut and the end of each bolt. Tighten the nuts 60 5° more.8. Repeat Steps 1 through 7 for the remainder of the pistons.END BY:a. install cylinder head assemblyb. install oil panDisassemble Pistons And Connecting Rods
START BY:a. remove pistons and connecting rods 1. Remove the rings from the piston with tool (A). 2. Remove the bearings from the connecting rod and connecting rod cap.3. Remove snap rings (3), pin (1) and connecting rod (2) from the piston. 4. See Use Of Piston Pin Bearing Removal And Installation Tools, Special Instructions, Form No. SMHS7295 for more information concerning removal and installation of piston pin bearings.5. Heat the connecting rod to a temperature of 176° to 260°C (350° to 500°F). Put 5P8654 Spacer (11) in the base plate. Put the connecting rod on the base plate of tooling (B).6. Put the connecting rod piston pin bearing end in the center of the port assembly of tooling (B). Install pin (6) in the center of the bore for the connecting rod bearings.7. Install 5P8653 Adapter (9). Put the hole in the adapter in alignment with the hole in the base plate of tooling (B).8. Install clamp bar (10) and clamp pin (7).9. Install new piston bearing (5) on adapter (9). The old bearing is pushed out by tooling (B) as the new bearing is installed.10. Put 5P8645 Adapter (8) in position as shown with the taper side down. The piston pin bearing joint must be in alignment with the hole in adapter (9) and the base plate of tooling (B).11. Put pusher (4) on adapter (8).12. Use tooling (B) to push the new piston pin bearing into the connecting rod until adapter (8) of tooling (B) makes full contact with the connecting rod surface.13. Remove the connecting rod and the old piston pin bearing from tooling (B).14. Check the piston pin bearing bore diameter after the bearing is installed. The correct dimension is 38.125 0.008 mm (1.5010 .0003 in.).Assemble Pistons And Connecting Rods
1. Install connecting rod (1) in the piston with the bearing tab groove (slot) on the same side as the hole (crater) in the top of the piston.2. Install piston pin (2) and snap ring (3).3. When old pistons are to be used again, clean and measure the pistons according to Guideline For Reusable Parts Pistons And Liners, Form No. SEBF8001.4. Install the spring for the oil ring. Install the oil ring with tool (A). The gap in the ring must be approximately 180° from the oil ring spring connections.5. Install the compression ring with tool (A). The side of the ring that has the identification "TOP" must be toward the top of the piston. The gaps in the rings must be approximately 120° apart. Compression rings that do not have identification must be installed with the edge that has the bevel toward the top of the pistons.6. Install connecting rod bearings.END BY:a. install pistons and connecting rods