896167A01 Mercury RESERVOIR KIT

Illustration 1 g01413469
(1) Bore for the cylinder liner (A) The dowels extend past the end of the cylinder block by the following distance. ... 10.0 0.5 mm (0.39 0.02 inch) (B) The dowels extend past the end of the cylinder block by the following distance. ... 10.0 0.5 mm (0.39 0.02 inch) (D) The dowels extend past the end of the cylinder block by the following distance. ... 10.0 0.5 mm (0.39 0.02 inch)
Illustration 2 g01413742
Section C-C
Bore sizes in the cylinder block prior to installation of the cylinder liner:Dimension (E) ... 151.50 0.03 mm (5.965 0.001 inch)Dimension (F) ... 149.80 0.30 mm (5.898 0.012 inch)Dimension (G) ... 148.00 0.03 mm (5.827 0.001 inch)Dimension (H) ... 141.90 0.15 mm (5.587 0.006 inch)
Illustration 3 g01413748
Front face of the cylinder block
The flatness of the top contact surface of the cylinder block must be within 0.05 mm (0.002 inch) for any 150 mm (5.9 inch) section of the surface. (2) Torque for the bolt that holds the piston cooling jet ... 30 7 N m (22 5 lb ft) (3) Apply 6V-6640 Sealant to the outside diameter of the cup plug prior to installation into the cylinder block. Install the cup plug to the following depth. ... 1.25 0.25 mm (0.049 0.010 inch)Use the following procedure to install the main bearing cap bolts (4):
The main bearing caps are numbered 1 through 7. Ensure that the main bearing caps are in the correct location. The part number on the main bearing cap must face to the right side and toward the front of the block. Orient the main bearing cap correctly in the cylinder block. If caps are oriented correctly, the tab slots that are in the block and in the main bearing caps will be adjacent.Note: Use SAE 30 oil or molybdenum grease to lubricate the threads and the washer face of the main bearing cap bolts.
Torque the main bearing cap bolts to 95 N m (70 lb ft).
Put an alignment mark on each cap and bolt.
Rotate the bolts for an additional turn in the clockwise direction to 90 degrees. (5) Main bearing capWidth of the main bearing cap ... 175.000 0.020 mm (6.8897 0.0008 inch)Width of the cylinder block for the main bearing cap ... 175.000 0.018 mm (6.8897 0.0007 inch) (J) Diameter of the camshaft bores ... 81.000 0.015 mm (3.1890 0.0006 inch) (K) The dowels extend past the top surface of the cylinder block by the following distance. ... 10.0 0.5 mm (0.39 0.02 inch) (M) Distance from the centerline of the crankshaft bore to the top surface of the cylinder block ... 387.00 0.15 mm (15.236 0.006 inch) (N) Bore in the cylinder block for the seven main bearings ... 116.000 0.013 mm (4.5669 0.0005 inch) (P) Distance from the centerline of the crankshaft to the bottom surface of the cylinder block ... 120.0 mm (4.72 inch)Camshaft Bearing Position
Illustration 4 g01413770
Section L-L
Install the sleeve bearings into the cylinder block at the location that is specified. The distance that is listed below is measured from the front face of the cylinder block.Dimension (R) ... 954.1 mm (37.56 inch)Dimension (S) ... 815.2 mm (32.09 inch)Dimension (T) ... 659.2 mm (25.95 inch)Dimension (U) ... 503.2 mm (19.81 inch)Dimension (V) ... 347.2 mm (13.67 inch)Dimension (W) ... 191.2 mm (7.53 inch)Dimension (X) ... 35.2 mm (1.39 inch)
Camshaft bearings must be installed into their correct position. Failure to do so will result in engine damage.
Illustration 5 g01413787
Section Y-Y
(6) Bearing joint (AB) Orient the oil hole of the sleeve bearing (7) to the following angle. ... 45 degrees
Illustration 6 g01413792
Section Z-Z
(8) Bearing joint (AC) Orient the oil hole of the sleeve bearing (9) to the following angle. ... 45 degrees
Illustration 7 g01413796
Section AA-AA
(10) Bearing joint (AD) Orient the oil hole of the sleeve bearing (11) to the following angle. ... 115 degreesNote: The width of the number 1 sleeve bearing to the number 6 sleeve bearing is 33.4 0.5 mm (1.31 0.02 inch). The width of the number 7 sleeve bearing is 28.0 0.5 mm (1.10 0.02 inch). The number 1 sleeve bearing has a 5.0 0.5 mm (0.20 0.02 inch) wide single groove on the inside diameter. The width of the single groove on the outside diameter of the number 2 sleeve bearing to the number 6 sleeve bearing is 8.0 0.5 mm (0.32 0.02 inch). The number 7 sleeve bearing has a 3.2 0.5 mm (0.13 0.02 inch) wide single groove on the outside diameter.