823038 Mercury RECOIL STARTER ASSEMBLY

Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-6357(1)
or
8T-3022(2) Connecting Rod Guide 1
B 235-0612 Lift Bracket 1
C 136-1452 Retaining Ring Pliers As 1
D 318-4874 Ring Expander Gp 1
E 443-4072 (3)
or
443-4073 (4) Cover 1
G 1U-8692 Piston Pin Guide 1
H 4C-9043 Piston Ring Compressor Gp 1
J 8T-5096
or
369-2607 Dial Indicator 1
K - Bel-Ray Molylube: PN. 67700 -
L 384-8910 Hydraulic Wrench
(1) Use with V-engines
(2) Use with in-line engines
(3) For 6 and 8 cylinders
(4) For 12 and 16 cylinders
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g03374611Note: Ensure that there is no damage to the shank of connecting rod bolt (3) prior to the installation of heat shrink tube (10).Note: Ensure that the shanks of connecting rod bolts (3) are free of debris and oil prior to installation.
If a new heat-shrink tube will be installed, follow Step 1.a through Step 1.d.
Clean the shank of connecting rod bolt (3) free of debris and oil.
Slide the new heat shrink tube (10) onto connecting rod bolt (3). Install the new heat shrink tube (10) to Dimension (Y). Dimension (Y) is 1.50 mm (0.059 inch).
Use a suitable heat gun or use a suitable oven to shrink the heat shrink tube (10) onto connecting rod bolt (3). If a suitable oven is used, heat the connecting rod bolt (3) and heat shrink tube (10) at a temperature of 135° 14° C (275° 57°F) for 10 minutes.
After installing the new heat shrink tube (10) onto connecting rod bolt (3), allow connecting rod bolt (3) to cool. Ensure that heat-shrink tube (10) does not have any bumps or wrinkles. Ensure the heat-shrink tube (10) does not move under light finger pressure.
Illustration 2 g03376355Note: Ensure that piston (4) is clean and meets reuse guidelines.
Before the piston rings are installed on the piston, check the end gap on each piston ring. Refer to Specifications, "Piston and 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.
Use Tooling (D) to install the piston rings on piston (4).
The piston ring gaps should be separated by 120 degrees. Install the piston rings in the following manner:
Install the piston ring expander on the piston. The ends of the oil ring spring should be installed 180 degrees from the oil ring end gap. The white portion of the oil ring spring must be visible at the ring end gap.
The third piston ring must be installed with Mark "UP-3" upward.
The second piston ring must be installed with Mark "UP-2" upward.
The top ring must be installed with Mark "UP-1" upward.
After the piston rings have been installed, measure the side clearance between the piston rings and the piston grooves. Refer to Specifications, "Piston and Rings".
Locate Mark (4a) on the top of piston (4). Draw an alignment mark on the side of the piston.Note: Mark (4a) is a mill dot on the top of piston (4).
Illustration 3 g03374939
Attach a suitable lifting device to connecting rod (7). The weight of connecting rod (7) is approximately 59 kg (130 lb). Install the upper half of connecting rod bearing (8) in connecting rod (7). Ensure the tabs of the upper half of connecting rod bearing (8) are engaged with the slots in connecting rod (7).
Install Tooling (A) onto the connecting rod bolts. Tooling (A) will hold the upper half of connecting rod bearing (8) in position. Apply clean engine oil to the face of the upper half of connecting rod bearing (8).
Position connecting rod (7) in a VERTICAL position on a suitable surface. Hold the connecting rod (7) to prevent the connecting rod from falling. Remove the suitable lifting device from connecting rod (7).
Illustration 4 g03374721
Attach Tooling (B) and a suitable lifting device to piston (4). The weight of piston (4) is approximately 40 kg (88 lb). Align Mark (4a) with the tab side of the connect