38628 Mercury PULLER HEADD

Illustration 1 g03347646
Front view of the engine
Typical example
Illustration 2 g03347647
Marks for tightening main bearings
Typical example
Table 1
Item Qty Part Specification Description
The top face of the cylinder block, bottom surface of spacer plate (1) and both sides of plate gasket (2) must be free of fuel, oil, water, gasket adhesives, assembly compounds and any other contaminants during assembly.
1 2 225-3100 Spacer Plate Thickness is 8.585 0.025 mm (0.3380 0.0010 inch).
2 2 354-8484 Plate Gasket Apply adhesive to block side of gasket-plate only, no adhesive should be on opposing side of gasket-plate. Adhesive to be applied as an even, minimal coat(Skim coat). Minimal to zero material should squeeze out of joint after assembly has been torqued. No adhesive should contact water ferrule or liner lip.
Thickness of plate gasket that is between cylinder block and spacer plate is 0.20 0.02 mm (0.008 0.001 inch).
3 4 7C-9614 Taperlock Plug Before assembly, apply Loctite low breakloose PST on the threads.
Torque to 80 15 N m (60 11 lb ft).
A 4 4N-1650 Dowel Extension of the dowels on the left bank and right bank from the cylinder block is 18.5 0.5 mm (0.73 0.02 inch).
4 7 232-7607 Crankshaft Cap The crankshaft caps must be installed with the identifying marks toward the front of the engine. The number of the main bearing cap must also match the cast number on the left side of each main bearing saddle.
B - - Bore in cylinder block for main bearing is 129.891 0.013 mm (5.1138 0.0005 inch).
C - - The distance from the centerline of the crankshaft bearing bore to the top of the cylinder block is 419.10 0.15 mm (16.500 0.006 inch).
D - - The distance from the centerline of the crankshaft bearing bore to the bottom of the cylinder block is 165.10 0.10 mm (6.500 0.004 inch).
E - - The width of the slot for the crankshaft cap (4) is 236.00 0.05 mm (9.291 0.002 inch).
Width of crankshaft cap (4) is 235.500 0.025 mm (9.2716 0.0010 inch).
5 14 365-4307 Bolt Use the following procedure to install the crankshaft cap:
6 14 3P-1323 Bearing Cap Bolt
1. Apply clean engine oil on the threads of the bolts (6). Loosely install the bolts (6).
2. Apply clean engine oil on the threads of the side bearing cap bolts (5) and the washers. Loosely install the side bearing cap bolts (5) and the washers.
3. Tighten tab end of the main bearing cap bolt (6) to 258 14 N m (190 10 lb ft).
4. Tighten opposite end of the main bearing cap bolt (6) to 258 14 N m (190 10 lb ft).
5. Put a mark on each bolt (6) and each crankshaft cap (4). See Illustration 2.
6. Again, tighten opposite end of the main bearing cap bolt from the mark to an additional angle (F) of 120 5 degrees.
7. Again, tighten tab end of the main bearing cap bolt from the mark to an additional angle (F) of 120 5 degrees.
8. Tighten the side bearing cap bolts (5) that are at the opposite end of the main bearing cap to 80 10 N m (60 7 lb ft).
9. Tighten the side bearing cap bolts (5) that are at the tab end of the main bearing cap to 80 10 N m (60 7 lb ft).
10. Again, tighten the side bearing cap bolts (5) that are at the opposite end of the main bearing cap to 80 10 N m (60 7 lb ft).
11. Again, tighten the side bearing cap bolts (5) that are at the tab end of the main bearing cap to 80 10 N m (60 7 lb ft).
Illustration 3 g03347648
Right side of the engine
Typical example
Table 2
Specification for 350-5438 Cylinder Block Gp and 349-2859 Cylinder Block Gp
Item Qty Part Specification Description
7 1 214-1728 Stud Apply blue Loctite 540 to the pipe threads of stud. Tighten the stud with the coated pipe threads into the cylinder block.
8 3 6L-4428 Taperlock Stud Torque to 35 5 N m (26 4 lb ft).
G 4 4N-0683 Dowel Extension of dowels from the rear face of the cylinder block and from the front face of the cylinder block is 19.0 0.5 mm (0.75 0.02 inch).