804532 Mercury O-RING KIT (16 PER KIT)

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     6V-6640     Sealant     1    
B     -     Guide Studs
(M8 by 70 mm)     2    
C     319-6486     Alignment Tool     1    
- studs
(M10 by 50 mm)     3    
D     -     Straight Edge     1    
E     1U-6396     O-Ring Assembly Compound     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the front housing is clean and free from damage. If necessary, replace the front housing.Install blanking plugs to a new front housing. Use Tooling (A) to seal all D-plugs.
Clean all the gasket surfaces of the cylinder block.
Illustration 1 g01337987
If necessary, install thrust washer (10) into the recess in the cylinder block. Refer to Disassembly and Assembly, "Camshaft - Install" for more information.
Illustration 2 g02718660
Install Tooling (B) to the cylinder block. Refer to Illustration 2.
Align a new gasket (6) with Tooling (B) . Install the joint to the cylinder block.Note: Ensure that two circular Tabs (X) on the gasket are engaged in two Holes (Y) in the cylinder block.
Illustration 3 g01338001
Typical example
Install Tooling (C) to the cylinder block.
Install the front housing over Tooling (B) and Tooling (C) onto the cylinder block.
Illustration 4 g01338002
(7) M8 by 20 mm (8) M8 by 35 mm (9) M8 by 25 mm
Install new bolts (9) to front housing (3) hand tight.
Remove Tooling (B) .
Loosely install bolts (7) and bolts (8) . Refer to Illustration 4 for the correct position of the bolts.
Align the bottom face of front housing (3) to the lower machined face of the cylinder block. Use Tooling (D) and a feeler gauge in order to check the alignment between the front housing and the cylinder block. Refer to Illustration 3. Refer to Specifications, "Front Housing and Covers" for further information.
Tighten bolts (9) in the sequence that is shown in illustration 5 to a torque of 28 N m (248 lb in).
Repeat Step 11 to ensure that the bottom face of front housing (3) to the lower machined face of the cylinder block are still aligned.
Illustration 5 g01338003
Tighten bolts (7) , bolts (8) in the sequence that is shown in illustration 5 to a torque of 28 N m (248 lb in).Note: Ensure that the housing and the cylinder block are correctly aligned.
Remove Tooling (C) from the cylinder block.
Install a new crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front Seal - Remove and Install".
Illustration 6 g01337982
Typical example
Install new O-ring seal (4) and new O-ring seal (5) to bypass tube (2) . Use Tooling (E) in order to lubricate the O-ring seals. Install bypass tube (2) to the cylinder head. Install bolts (1) . Tighten the bolts to a torque of 22 N m (195 lb in).End By:
Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install".
Install the timing gears. Refer to Disassembly and Assembly, "Gear Group (Front) - Install".
If the engine has an accessory drive, install the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive - Remove and Install".
Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Install".
Install the vibration damper and pulley. Refer to Disassembly and Assembly, "Vibration Damper and Pulley - Install".
If necessary, install the alternator. Refer to Disassembly and Assembly, "Alternator - Install".
Install the fan and pulleys. Refer to Disassembly and Assembly, "Fan - Remove and Install".
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Fill" for the correct procedure.