878414A 1 Mercury PISTON ASSEMBLY

Table 1
Required Tools
Tool Part Number Part Description Qty
A 6V-6640 Sealant 1
B - Guide Studs
M8 by 40 mm 2
C 231-8847 Alignment Tool 1
- Bolts
M10 by 50 mm 3
D 1U-6396 O-Ring Assembly Compound 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
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.
Ensure that the front housing is clean and free from damage. If necessary, replace the front housing. If necessary, install blanking plugs to a new front housing. Use Tooling (A) in order to seal all D-plugs.
Clean all the gasket surfaces of the cylinder block.
Illustration 1 g02198913
Illustration 2 g02198914
Inspect dowel (12) and dowel (13) for damage. If necessary, replace the dowels in the cylinder block.
Install thrust washer (11) into the recess in the cylinder block. Refer to Disassembly and Assembly, "Camshaft - Install" for more information.
Install Tooling (B) to the cylinder block. Refer to Illustration 2.
Align a new gasket (10) with Tooling (B). Install the gasket to the cylinder block. Note: Ensure that two circular Tabs (X) on the gasket are engaged in two Holes (Y) in the cylinder block. Ensure that dowel (12) in the cylinder block is engaged on the gasket.
Install Tooling (C) to the cylinder block.
Install the front housing over Tooling (B) and Tooling (C) onto the cylinder block.
Illustration 3 g02198915
(7) M8 by 20 mm
(8) M8 by 35 mm
(9) M8 by 25 mm
Install new bolts (9) to front housing (4) hand tight.
Remove Tooling (B).
Loosely install bolts (7) and bolts (8) finger tight. Refer to Illustration 3 for the correct position of the bolts.
Illustration 4 g01998054
Tighten bolts (7), bolts (8) and bolts (9) in the sequence that is shown in Illustration 4 to a torque of 28 N m (248 lb in).
Remove Tooling (C) from the cylinder block.
Illustration 5 g02198874
Install new O-ring seal (5) and O-ring seal (6) to bypass tube (1). Use Tooling (D) in order to lubricate the O-ring seals.
Install bypass tube (1) to the cylinder head. Install bolts (3). Tighten the bolts to a torque of 9 N m (80 lb in)
Install a new cable strap (2) to the wiring harness assembly. End By:
Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install" for the correct procedure.
Install the timing gears. Refer to Disassembly and Assembly, "Gear Group (Front) - Install" for the correct procedure.
If the engine has an accessory drive, install the accessory drive. Refer to Disassembly and Assembly, "Accessory Drive - Remove and Install" for the correct procedure.
Install the engine oil pan plate. Refer to Disassembly and Assembly, "Engine Oil Pan Plate - Remove" for the correct procedure.
Install the crankshaft pulley. Refer to Disassembly and Assembly, "Vibration Damper and Pulley - Install" for the correct procedure.
Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install" for the correct procedure.
Install the fan. Refer to Disassembly and Assembly, "Fan - Remove and Install" for the correct procedure.
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Fill" for the correct procedure.