11143912 Mercury OWNERS MANUAL (BLACK 135/150/175/200)

Table 1
Required Tools    
Tool    Part Number    Part Description    Qty    
A     6V-6080     Torque Multiplier     1    
5P-1748 Socket     1    
4C-9451 Rear Idler Gear Wrench     1    
4C-9452 Rear Idler Gear Wrench     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g00611176
Illustration 2 g00611187
If the bearing was removed from gear (8) , install the bearing in the gear. The bearing must be located at a distance of 2.50 0.50 mm (0.10 0.020 inch) below the surface of the side of the gear. This distance is measured on the gear with the smaller shoulder. The inside diameter of the gear should be 124.980 0.020 mm (4.9210 0.0008 inch) after installation.
Put gear (10) in position on gear (8) . Install bolts (6) .
Put the following components in position on shaft (5) : gear (8) and other gear (10) . Install bolts (9) . Do not tighten the bolts at this time.
Attach a suitable lifting device to gear (10) . Put gear (10) and shaft (5) in position in the rear housing through the opening for the camshaft drive gear.
Fasten a hoist to the gear (10) through the opening in the rear housing. This opening is for the accessory drive. Remove the hoist through the opening of the drive gear.
Align the teeth on gear (10) with the teeth on gear (12) . Put shaft (5) in position on the cylinder block. Install four bolts (11) . Tighten the bolts to a torque of 200 25 N m (150 18 lb ft).
Tighten bolts (9) .
If the bearings were removed from gears (2) , install the bearings in the gears. The bearings must be 2.5 0.5 mm (0.098 0.02 inch) below the flat surface of the gear. The inside diameter of the bearings should be 150.002 0.020 mm (5.9056 0.0008 inch) after installation.
Put gear (2) and retainer (4) in position on shaft (3) . Install the bolts that hold these components in place.
Attach a suitable lifting device to gear (2) . Put the gear and the shaft in position on the cylinder block through the opening for the camshaft drive gear in the rear housing. Install four bolts (1) . Tighten the bolts to a torque of 475 50 N m (350 37 lb ft).
Repeat Step 9 and Step 10 for the other idler gear.
Illustration 3 g00664018
Note: The center lobe of the camshaft segment on the G3612 and the G3616 Engine is narrower than the center lobe on the 3612 or the 3616 Diesel Engine.
Put spacer (14) in position on the end of drive shaft (13) .
Align the dowel in shaft (13) with the dowel hole in camshaft segment (16) . Install bolts (15) . Tighten all of bolts (15) by hand.
Illustration 4 g00611192
Put plate (20) in position and install bolts (18) .
Put plate (17) in position on drive shaft (13) and install bolts (19) .
Illustration 5 g00664022
Note: The center lobe on the camshaft segment of the G3612 and the G3616 Engine is narrower than the center lobe on the camshaft segment of the 3612 and the 3616 Diesel Engine.
Be sure that camshaft timing pin (21) is installed in both camshafts.
Illustration 6 g00611198
Put plate (23) in position on drive gear (22) and install bolts (24) .
Attach a suitable lifting device to drive gear (22) . Put the drive gear in position on the camshaft. Install washer (25) and bolt (26) . Tighten bolt (26) by hand.
Remove the crankshaft timing pin from the timing location.Note: If the crankshaft is turned more than 20°, interference between the pistons and the valves may occur.
Turn the flywheel in the direction that is opposite of the normal rotation to a maximum setting of 20°.
Be sure that bolts (26) are hand tightened. Turn the flywheel in the direction of the normal engine rotation until the crankshaft timing pin can be installed in the crankshaft. This procedure holds the backlash in the timing gears in the direction of the normal engine rotation.Note: If the location of the crankshaft timing pin is missed, do not turn the flywheel in the opposite direction in order to install the timing pin. If the crankshaft timing pin is missed, repeat Step 20 through Step 21.
Remove the camshaft timing pins.
Use Tooling (A) and tighten bolts (26) to a torque of 2000 275 N m (1480 200 lb ft).
Carefully hit bolt (26) with a hammer. Repeat Step 23. Repeat this procedure until the torque does not change.