817275A 2 Mercury HOUSING KIT, Upper Water Pump

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Guide Studs
M8 by 50 mm 4
B 6V-6640 Sealant 1
Ensure that wiring harness are correctly routed and the cable straps are not over tightened. Over tightening of the cable straps will damage the wiring harness convoluting.
Illustration 1 g02193294
If necessary, follow Step 1.a through Step 1.d in order to assembly the engine oil cooler.
Ensure that engine oil cooler matrix (16) is clean, free from damage and restriction. Replace engine oil cooler matrix (16) if damaged or restricted.
Ensure that housing (19) is clean and free from damage. Replace spacer plate (19) if damaged.
Position new gaskets (17) onto engine oil cooler matrix (16). Install engine oil cooler matrix (16) to housing (19).
Install nuts (18) to the assembly of oil cooler (6). Tighten the nuts to a torque of 44 N m (32 lb ft).
Illustration 2 g02194374
Illustration 3 g02194313
Illustration 4 g02194394
Tightening sequence for the oil cooler with the high mounted oil filter
Clean the gasket surfaces of the cylinder block.
Install Tooling (A) into Position (C).
Position a new gasket (15) (not shown) onto Tooling (A).
Install assembly of oil cooler (6) to cylinder block. Install bolts (14) to the assembly of oil cooler (6). Tighten bolts (14) finger tight. Note: Ensure that the bolts of different lengths are installed in the correct position. Ensure that any brackets for the tube assemblies are location and correctly orientated.
Remove Tooling (A) and install remaining bolts (14).
Install oil filter base and install the bolts for the oil filter base finger tight. Refer to Illustration 4 and refer to Disassembly and Assembly, "Engine Oil Filter Base - Remove and Install" for the correct procedure.
Tighten bolts (14) to a torque of 22 N m (195 lb in) in sequence that is shown in Illustration 4. Tighten the remaining bolts that secure oil filter base to a torque of 22 N m (195 lb in).
Illustration 5 g02193293
Install new cable straps to engine wiring harness (3) that secure the wiring harness assembly to engine oil cooler (6).
Connect plastic tube assembly (1) to crankcase breather (2). Install the plastic tube assembly to the clips. Refer to Disassembly and Assembly, "Crankcase Breather- Install" for the correct procedure.
Connect plastic tube assembly (5) to crankcase breather canister (2) and crankcase breather valve (8). Refer to Disassembly and Assembly, "Crankcase Breather- Install" for the correct procedure.
Position clamp (13) onto engine oil cooler (6). Install bolt (12) and tighten the bolt to a torque 10 N m (88 lb in).
Position bracket (7) onto engine oil cooler (6) and install bolts (4). Tighten the bolt to a torque of 18 N m (159 lb in). Note: Ensure that locating pin for the bracket is correctly located into the engine oil cooler.
Install a new seal (11) (not shown) to the tube assembly. Apply Tooling (B) to nut (9).
Install the tube assembly to the engine oil pan. Install bolt (10) to the bracket for tube assembly.
Tighten bolt (10) to a torque of 22 N m (195 lb in).
Tighten nut (9) to a torque of 18 N m (159 lb in).
Fill the cooling system to the correct level. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.
Check level of the engine lubricating oil. Refer to Operation and Maintenance Manual, "Engine Oil Level - Check" for the correct procedure. End By:
Install the mounting bracket for the Electronic Control Module (ECM) . Refer to Disassembly and Assembly, "ECM Mounting Bracket- Remove and Install" for the correct procedure.