835427A00 Mercury GASKET SET, Powerhead

Illustration 1 g06506950
Table 1
Item Qty Part Specification Description
- During assembly, bottom of the plate, top of the block, and both the sides of the gasket plate must be free of all visible fuel, oil, water and gasket adhesives, assembly compounds, or any other contaminates.
1 3 8T-2928 O-Ring Seal Lightly lubricate the bore with P-80 or Petro Gel Amber Lubricant.
2 3 8T-2929 O-Ring Seal During assembly, apply Krytox® GPL-205 to secure O-rings.
3 3 4W-4813 Plug Torque to 100 15 N m (74 11 lb ft).
4 4 5F-9657 O-Ring Seal Lightly lubricate the bore with P-80 or Petro Gel Amber Lubricant.
5 14 101-1198 Camshaft Bearing All centerlines through oil holes in the camshaft bearings and the camshaft bearing junctions must be positioned as shown in Illustration 1 on each side of cylinder block.
Oil holes must be positioned from horizontal at an angle (D3) of 20 5 degrees as shown in Illustration 1.
Bore in the cylinder block for camshaft bearing is 98.00 0.02 mm (3.858 0.001 inch).
6 8 6V-3348 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.
D1 24 8T-0099 Dowel Extension of the dowel from the top face of the cylinder block is 21 1 mm (0.8 0.1 inch).
D2 12 197-7008 Dowel Extension of the dowel from the top face of the cylinder block is 21 1 mm (0.8 0.1 inch).
D4 7 223-1696 Crankshaft Bearing Cap Width of the crankshaft bearing cap is 340.030 0.015 mm (13.3870 0.0006 inch).
Width of cylinder block for main bearing cap is 339.985 0.015 mm (13.3852 0.0006 inch).
D5 - - New dimension from centerline of crankshaft bearing bore to the top of the cylinder block is 586 mm (23.1 inch).
D6 - - New dimension from centerline of crankshaft bearing bore to bottom of cylinder block (pan rails) is 230 mm (9.1 inch).
D7 - - Bore in the cylinder block for the main bearings is 169.742 0.020 mm (6.6827 0.0008 inch).
Illustration 2 g06506964
Section A-A
Table 2
Item Qty Part Specification Description
D8 1 7N-2047 Dowel Extension of the dowel from the rear face of the cylinder block is 6.0 0.5 mm (0.24 0.02 inch).
D9 2 7N-2047 Dowel Extension of the dowel from the front face of the cylinder block is 6.0 0.5 mm (0.24 0.02 inch).
L 2 4N-0683 Dowel Extension of the dowel from the rear face of the cylinder block is 19.0 0.5 mm (0.75 0.02 inch).
M 2 7N-2044 Dowel Extension of the dowel from the front face of the cylinder block is 40.0 0.5 mm (1.57 0.02 inch).
Illustration 3 g06506958
Tightening sequence
Table 3
Item Qty Part Specification Description
7 28 7X-7925 Bolt Use the following procedure to tighten the crankshaft bearing cap bolts:
1. Before assembly, lubricate the threads completely with clean engine oil.
2. Hand tighten the bolts in the tapped holes.
3. Tighten the bolts to 190 14 N m (140 10 lb ft) in the numerical sequence as shown in Illustration 3.
4. Again, tighten the bolts for an additional angle of 180 5 degrees.