810777 Mercury CYLINDER KIT (DESIGN I)

start by:a) remove piston cooling jets1. Drain the oil from the oil pan. 2. Use tool (A) to turn the engine flywheel to move counterweights (1) in position for removal. Remove counterweights (1) from the crankshaft through the side of the cylinder block.3. Use tool (A) and turn the engine flywheel to move the connecting rod bearing surface (journal) to the top center position. 4. Use tool (B) and loosen the four bolts that hold the main bearing cap in position.5. Hold the main bearing cap in position with a pry bar and remove the bolts and lower the bearing cap from the cylinder block.6. Remove the bearing caps from the side of the engine. The weight of the bearing cap is 16 kg (35 lb.). 7. Remove the lower bearing half (2) from bearing cap (3). 8. Remove thrust plates (4) from each side of the center main bearing.
If the crankshaft is turned in the wrong direction, the tab of the bearing will be pushed between the crankshaft and cylinder block. This can cause damage to either or both.
On the center main journal that has no oil hole, put a thin piece of soft material that will not damage the crankshaft journal against the end of the bearing, opposite the tab. Hit the bearing with the soft material until the tab of the bearing is free from the cylinder block. Remove the upper half of the main bearing. 9. Install tool (C) in the oil hole in the crankshaft journal and remove upper main bearing halves (5) as the crankshaft is turned and the bearing is moved out of the cylinder block.Install Crankshaft Main bearings
Make sure the upper and lower halves of bearings are installed so the bearing tabs fit into the notch in cylinder block and bearing caps.
Install the main bearings dry when the clearance checks are made. Put clean engine oil on the main bearings for final assembly. 1. Install tool (B) in the oil hole of the crankshaft. Put the upper bearing half (half with oil hole) in position on the crankshaft. Use tool (A) to turn the engine flywheel and push the bearing half in position with tool (B).2. Make sure the bearing caps are clean and install the lower bearing halves in the caps.
Do not use an impact wrench to tighten the bolts the additional 180 5° of a turn more.
When the bearing clearance is checked and the engine is in a vertical position, such as in the vehicle, the crankshaft will have to be lifted up and held against the upper halves of the main bearings to get a correct measurement with the Plastigage. The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, it is not necessary to hold the crankshaft up. Do not turn the crankshaft when the Plastigage is in position to check clearance.3. Check the bearing clearances with Plastigage as follows: a. Put a piece of the Plastigage on the surface of the lower bearing half.b. Install the main bearing caps with the word "FRONT" and the cast part number toward the front of the cylinder block. Each cap has a number on the bottom surface and must be installed in the same position as the correct number on the right side of the block pan rail. The procedure to tighten the main bearing cap bolts depends on the diameter of the bolts. There is a different procedure for 3/4 inch bolts and for 7/8 inch bolts.c. For tightening 3/4 inch diameter bolts, put clean engine oil on the bolts before assembly. Tighten the bolts in the number sequence shown with tool (D) to a torque of 136 14 N m (100 10 lb.ft.). Then, tighten the bolts in the number sequence shown with tool (D) 210 5° of a turn more. For tightening 7/8 inch diameter bolts, put clean engine oil on the bolts before assembly. Tighten the bolts in the number sequence shown with tool (D) to a torque of 190 14 N m (140 10 lb.ft.). Then, tighten the bolts in the number sequence shown with tool (D) 180 5° of a turn more.d. Remove the caps and measure the Plastigage. The main bearing clearance must be 0.122 to 0.241 mm (.0048 to .0095 in.). 4. Put clean engine oil on thrust plates (5) and install them on each side of the center main bearing with the grooves in the plates against the crankshaft. 5. Put clean engine oil on bearings (7) and put bearing caps (6) in position and tighten the bolts as in Step 3.
Each counterweight has a number and must be installed in the same position as the correct number on the crankshaft mounting pad to prevent damage to the crankshaft when the engine is run. Also do not use an impact wrench to tighten the bolts the additional 120 5° of a turn more.
6. Make sure the dowels are in position and install counterweights (8) on the crankshaft. Put 2P2506 Thread Lubricant on the bolts and tighten them evenly to a torque of 50 5 N m (37 4 lb.ft.). Then tighten the bolts 120 5° of a turn more. 7. Check the crankshaft end play with tooling (C). The end play is controlled by the thrust plates on the center main bearing. End play with new bearings must be 0.15 to 0.50 mm (.006 to .020 in.).8. Fill the engine with oil to the correct level.end by:a) install piston cooling jets