810763 Mercury POWER JET, POWER

Table 1
Required Tools
Tool Part Number Part Description Qty
A 136-1452 Retaining Ring Pliers As 1
B 318-3117 Ring Expander Gp 1
C 178-5063 Guide 2
D 235-0612 Lift Bracket (1) 1
E 229-3639 Overhaul Protection Gp 18
G 4C-5719 Piston Ring Compressor 1
H 8T-5096 Dial Indicator Group (2) 1
J 6V-4876 Lubricant -
K 186-1531 Lubricant -
(1) Part of the 235-0632 Cylinder Installation Tool
(2) An electronic 1U-8869 Dial Indicator may also be used.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: Tooling (E) provides all protective covers and plugs for one cylinder. Use these protective covers to maximize protection during maintenance procedures.
Illustration 1 g00704192
Use a suitable lifting device to place piston (3) with the piston skirt (bottom) on a piece of cardboard or on another suitable clean even surface. The weight of piston (3) is approximately 46 kg (101 lb).
Use the following Steps to install the piston rings:
Do not install the piston rings without the use of the piston ring expander. Piston ring breakage and piston damage may result if the piston ring expander is not used.
Note: Use Tooling (B) to install the oil ring first. The oil ring is the bottom piston ring on piston (3). A spring is on the inner diameter of the grooved oil ring. The middle of the spring is marked with a white band. Orient the ends of the spring to 180 degrees opposite side of the ring gap. The white band on the spring will be visible through the ring gap.
Grip the oil ring and grip the spring in the inner diameter of the ring. Separate the two ends of the spring until the oil ring is expanded enough to be installed over the piston. After the oil ring is over the bottom groove in the piston, release the spring and allow the oil ring to contract into the groove. Make sure that the white band on the spring is visible through the ring gap.
Use Tooling (B) to install the second compression ring. The second compression ring is the middle piston ring on piston (3). Install the compression ring with the side marked "UP 2" toward the top of the piston. Install the compression ring in the middle groove of the piston. Orient the ring gap to 120 degrees away from the oil ring gap.
Use Tooling (B) to install the first compression ring. The first compression ring is the top piston ring on piston (3). Install the compression ring with the side marked "UP 1" toward the top of the piston. Orient the ring gap to 120 degrees away from the adjacent ring gap.
Illustration 2 g01214071
Mark the side of the piston crown above Dimple (X). When you install the connecting rod, make sure that the side for connecting rod cap (1) is oriented toward Dimple (X) on top of piston (3).
Illustration 3 g00700650
Use a suitable lifting device to carefully place piston (3) on the piston crown. The weight of piston (3) is approximately 46 kg (101 lb).Note: Provide support for the piston and the connecting rod in order to prevent the assembly from falling when the piston pin is installed.
Attach a suitable lifting device to the bearing end of connecting rod (2). The weight of connecting rod (2) is approximately 92 kg (203 lb). Carefully lower connecting rod (2) into piston (3). Make sure that the side for the connecting rod cap is oriented toward Dimple (X) on top of the piston crown.
Lubricate piston pin (5) with clean engine oil. Carefully install piston pin (5) into piston (3) and through connecting rod (2). The weight of piston pin (5) is approximately 22 kg (50 lb).
Use Tooling (A) to install pin retainers (4). Install the coined sides of the pin retainers toward the piston. Orient the gap between the ends of the pin retainers toward the connecting rod. Tap the pin retainers in order to be sure that the pin retainers are seated in the grooves in the piston.After assembly, measure the end play between piston pin (5) and pin retainers (4). The correct end play is 0.60 mm (0.024 inch).
Carefully lay the piston and connecting rod sideways.
Attach Tooling (D) and a suitable lifting device to the top of piston (3). The weight of the piston and the connecting rod is approximately 160 kg (353 lb).
Carefully lift the piston and connecting rod as a unit.
Illustration 4 g01214092