803729A 2 Mercury GEAR HOUSING ASSEMBLY

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Loctite 5970
Silicone Sealant 1
B - Guide Bolt
M8 x 1.25 by 35 mm 2
C - Loctite 506 1
D 1U-6396 O-Ring Assembly Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shorten component life.
Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
Illustration 1 g03022878
If a new front housing is being installed, it will be necessary to remove plug (7) in Position (Y) for engines that are equipped with any accessory drive in order to maintain the lubrication of the accessory drive.
If the accessory drive was removed but will not be installed, the oil gallery in Position (Y) must be plugged. Follow Step 3.a through Step 3.c in order to maintain engine oil circulation.
Apply Tooling (C) to plug (7).
Install plug (7) into front housing (1).
Tighten plug (7) to a torque of 15 N m (133 lb in).
Illustration 2 g02951196
Illustration 3 g02729111
Front housing sealant path.
Illustration 4 g02729108
Thoroughly clean the gasket surface of the front housing (1) and the cylinder block.
If necessary, install dowels (6) (not shown) to the cylinder block.
Install Tooling (B) into the cylinder block in Positions (X).
Apply a 3mm bead of Tooling (A) to front housing (1) as shown in Illustration 3.
Install front housing (1) onto Tooling (B) and dowels (6) (not shown).
Apply Tooling (C) onto the threads of bolts (5).
Install bolts (5) into front housing (1) in available location finger tight.
Remove Tooling (B) from the cylinder block.
Illustration 5 g02951436
Install remaining bolts (5). Tighten the bolts in the sequence that is shown in Illustration 5 to a torque of 25 N m (221 lb in).
Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Install" for the correct procedure.
Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install" for the correct procedure.
Install the engine oil pan . Refer to Disassembly and Assembly, "Engine Oil Pan - Remove" for the correct procedure.
If necessary, install the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive - Remove and Install" for the correct procedure.
Illustration 6 g02951696
If necessary, follow Step 17.a through Step 17.c in order to install engine oil filler (2).
Install new O-ring seal (4) (not shown) onto engine oil filler (2).
Install engine oil filler (2) into front housing (1).
Install bolts (3) into engine oil filler (2). Tighten the bolts to a torque of 25 N m (221 lb in).
Illustration 7 g03025197
If necessary, install cover plate (8) to the front housing. Follow Step 18.a through Step 18.c in order to install the cover plate.
Install new O-ring seal (10) to cover plate (8). Apply Tooling (D) to O-ring seal (10).
Install cover plate (8) to the front housing.
Install bolts (9) to the cover plate and tighten the bolts to a torque of 25 N m (221 lb in).
If necessary, install the fan drive. Refer to Disassembly and Assembly, "Fan Drive - Remove and Install" for the correct procedure. End By:
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Fill" for the correct procedure.