896159A01 Mercury PISTON KIT

1. Loosen adjusting screws (2), and remove four bolts (1) and the washers from the rocker shaft assembly.2. Remove rocker shaft assembly (3) from the cylinder head assembly.3. Remove eight push rods (4) from the engine. Put identification marks on the push rods as to their location in the engine.Install Rocker Shaft Assembly And Push Rods
Typical Example1. Install push rods (4) in their original location in the cylinder block, and in the valve lifters.
Loosen adjusting screws (2) that are used to set the valve clearance. This will prevent a bent valve or push rod during installation.
Make sure the O-ring seal in the rear rocker arm support bracket is not damaged when the rear bolt is installed in the support bracket.2. Install a new O-ring seal in the rear rocker arm support bracket. Put 2P2506 Thread Lubricant on all of the bolts that hold the rocker shaft assembly in position except for the bolt that goes through the rear rocker arm support bracket.3. Put rocker shaft assembly (3) in position on the engine. Make sure the dowels located in the support brackets are in alignment with the dowel holes in the cylinder head assembly. Make sure the rocker arms are engaged with the push rods.4. Install four bolts (1) and washers that hold the rocker shaft assembly in position, and tighten them until they are finger tight. 5. Tighten the bolts that hold the rocker shaft assembly as follows:a. Tighten the bolts in number sequence to a torque of 155 N m (115 lb ft).b. Tighten the bolts in number sequence to a torque of 250 17 N m (185 13 lb ft).c. Tighten the bolts in number sequence to a torque (hand torque only) to 250 17 N m (185 13 lb ft).
Typical Example6. The assembled length of springs (5) at both ends of the rocker shaft assembly must be 1.50 0.25 mm (.059 .010 in). Remove or install the washers behind the springs to obtain the correct assembled length of the springs.7. Make an adjustment to the valves until the intake valve clearance is 0.38 mm (.015 in) and the exhaust valve clearance is 0.64 mm (.025 in). Tighten the nuts on adjustment screws (2) to a torque of 29 7 N m (21 5 lb ft). For the complete valve adjustment procedure, see Valve Clearance in Testing And Adjusting.End By:a. install valve coverRocker Shaft Assembly Disassemble
Start By:a. remove rocker shaft assembly and push rods 1. Remove O-ring seal (1) from the rear support bracket. A replacement of the O-ring seal must be made each time the head bolt is removed from the rear support bracket. 2. Remove retainer ring (6), washer (5), spring (4) and washers (3) from each end of the rocker shaft. Make a note of the number of washers (3) used at each end of the shaft. Remove rocker arms (2) from each end of the rocker shaft. All the rocker arms, springs, washers and brackets, except the rear support bracket, can be removed from the shaft. 3. Remove the pin from the rear support bracket with a hammer and punch. Remove rear support bracket (7) from the shaft.4. Remove remainder of the rocker arms, springs, washers and brackets from the shaft.5. Remove the plugs from each end of the shaft if necessary.Assemble Rocker Shaft Assembly
1. Install rocker arms (12), brackets (8), washers and springs (9) on the rocker shaft.2. Install rear support bracket (7) on the rocker shaft. Make sure the hole in the rear support bracket is in alignment with the hole in the rocker shaft.3. Put pin (10) in position in the bracket. 4. Install pin (3) through the bracket and shaft with a hammer.5. Pin (3) must extend 9.60 mm (.378 in) above the bracket. 6. Install O-ring seal (1) in the rear support bracket. Install rocker arm (2) the original number of washers, the spring, the washer and the retainer ring on the rocker shaft.7. Install the front support, rocker arm, original number of washers, the spring, the washer and the retainer ring on the rocker shaft.8. Install the plugs in each end of the rocker shaft, if they were removed.End By:a. install rocker shaft assembly and push rods