878242A 1 Mercury PISTON ASSEMBLY, Memory

Introduction
The correct installation of emissions critical components is vital to comply with the relevant emissions legislation. In addition, the document highlights the key assembly characteristics of other components that are transported loose. The assembly of the loose components is carried out by a representative of the customer.This Special Instruction is to be used in addition to the Service Manual. This document should be used as an assembly guide or a reference document when developing processes for production assembly facilities. Critical assembly characteristics such as tightening torques, component orientation, and assembly sequences should be followed to achieve the required product quality and emissions regulations.The Service Manual consists of the following manuals.
Operation and Maintenance Manual
Disassembly and Assembly
Troubleshooting
Systems Operation Testing and Adjusting
SpecificationsCustomers are permitted to paint the engine as received or as part of a power train sub assembly. These engines are supplied in gray primer.The customer must not paint the aftertreatment or exhaust systems, Electronic Control Module (ECM), starting motor, alternator, belts. The customer must not paint any filters and filter canisters. The canisters include fuel, air, oil, or diesel exhaust fluid (DEF).The customer must develop suitable plugs and masks to a standard equivalent to the engine assembly plant.The customer must prevent water ingress into the engine by maintaining a plugging standard equivalent to the engine assembly plant.Engine Air Cleaner for C3.6 and C2.8 Industrial Engines
Illustration 1 g03179402
Typical example
The engine air cleaner (1) can be supplied as a loose assembly. The engine air cleaner should be mounted horizontally. The dust exhaust port must be at the lowest point and positioned in a direction that is down.Note: Do not paint the dust exhaust port. Solvents and chemicals will shorten the usable life of the exhaust port.Note: There are several variations of engine air cleaner.Select the appropriate sized fasteners for the relevant air cleaner. Bolts should have a flanged head or be installed with a washer under the bolt head.Standard duty air cleanerTighten the M10 bolts to the following torque. ... 38.5 5.5 N m (28.4 4.1 lb ft)Heavy-duty air cleanerTighten the M8 bolts to the following torque. ... 15 3 N m (133 27 lb in)
Illustration 2 g03415816
Typical example
The position of the clamp (2) in relation to pipe or component bead (3) is crucial. Ensure that clamp (2) is installed on the correct side of the pipe or component beads (3).Air Temperature Sensor for C3.6 and C2.8 Industrial Engines
The air temperature sensor can be supplied loose.
Illustration 3 g03178776
Typical example
Install the sensor (1). Tighten the sensor to a torque of 20 3 N m (177 27 lb in).Note: Ensure that the O-ring is correctly installed to the sensor. Do not lubricate the O-ring seal.Diesel Exhaust Fluid (DEF) Dosing Control System on C3.6 Industrial Engines
DEF system components are supplied with caps and plug over connection points. Do not remove the caps and plugs before final assembly to ensure that cleanliness is maintained.DEF Cleanliness must be adhered to as outlined in ISO 22241.
DEF Tank Mounting and Installation on C3.6 Industrial Engines
Type 1 DEF Tank
Illustration 4 g06363555
Typical example
Illustration 5 g03707723
Typical example
Type 1 DEF tanks must be installed to the application with the following criteria:
The bottom of the DEF Tank must be fully supported by a structural platform. Full support is defined as a continuous material that is at least as large as the dimensions of the bottom of the tank. Structural is defined as being able to support full tank mass with application load without plastic deformation or failure.
An anti-friction rubber mat under the bottom of the tank is required. If the installation uses DEF tank stops, the anti-friction device must also be between the stops and the DEF tank.
Any metallic surfaces contacting the tank should be free of burrs, welds, foreign objects, and sharp edges.
The tank strap must be located correctly. The DEF tank has strap grooves (1) incorporated into the DEF tank to help keep the strap in place.
A minimum clearance of 9 mm (0.35433 inch) (X) on all sides is required with thick straps in the grooves.
The straps should be long enough to support the dimensions of the fasteners. If there is not enough free fastener length, assembly may be difficult.
A locked joint is a requirement and can be accomplished by using either a jam nut or lock nut.
The tank straps require a preload when installed. Thermal expansion and contraction of the tank may loosen the straps if a preload is not applied. The preload is a balance between enough preload to form the strap, to resist slip, to prevent excessive plastic deformation of the tank and having adequate life for the components.Show/hide tab