809561 1 Mercury DIAPHRAGM

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     6V-6192     Pliers     1    
B     7B-7974     Piston Ring Expander Gp     1    
C     5P-8639     Hydraulic Press (Connecting Rod Bearing)     1    
8F-0024 Hose Assembly     1    
1P-2375 Connecting Coupler     1    
1P-2376 Connecting Coupler     1    
5P-8651 Spacer     1    
5P-8649 Adapter     1    
5P-8650 Bushing Adapter     1    
9U-6600 Hydraulic Pump     1    Note: Prior to removal from the engine, the pistons and connecting rod assemblies were marked. The components must be reassembled together. The components must be installed in the original location in the engine. Do not interchange any of the components.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01018268
Illustration 2 g01017742
Use Tooling (C) to remove the old bearing and install the new bearing (7) at the same time. The adapter of Tooling (C) should make full contact with the surfaces of connecting rod (6) .Note: Orient the bearing joint within 5 degrees of either Location (X) .
The connecting rod must be heated for the installation of the piston pin bearing. Do not use a torch.
Raise the temperature of Length (Y) of connecting rod (6) to a temperature of 175 to 260 °C (347 to 500 °F). (Y) Maximum Length for heating the connecting rod ... 93 mm (3.7 inch)
Allow the connecting rod and the bearing to cool to room temperature.
Use a pin boring machine to machine the bore of bearing (7) to the correct diameter.Diameter of bearing bore ... 60.035 0.008 mm (2.3636 0.0003 inch)
Illustration 3 g01017728
Position the spring for the oil control ring in the oil ring groove in the piston body assembly.
Position oil control ring (3) over the spring. Position the oil control ring so that the gap is 180 degrees from the joint in the spring. Install the oil control ring on the piston with Tooling (B) .
Use Tooling (B) to install intermediate piston ring (2) with the side that has the identification "UP-2" toward the top of the piston.
Use Tooling (B) to install top piston ring (1) with the side that has the identification "UP-1" toward the top of the piston.
Position piston rings (1), (2), and (3) so the gaps are 120 degrees from each other.
Check the clearance between the ends of piston rings (1), (2), and (3). Refer to Specifications, "Pistons And Rings" for the specifications.
Put piston body assembly (4) in position on connecting rod (6). Apply clean engine oil to connecting rod pin (8) and install connecting rod pin (8). Install pin retainer (5) with Tooling (A). Make sure that pin retainers (5) are fully seated in the grooves of piston body assembly (4) .
Install connecting rod bearings (9) in connecting rod (6) and connecting rod cap (10). Make sure that rod bearings (9) are installed so that the bearing tabs fit into the notches in connecting rod (6) and in connecting rod cap (10).
Ensure that the dowels are installed in connecting rod cap (10) .End By: Install the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Install".