816519 Mercury ROD (USE W/ G/H CASTING #1659-9554C4)

Table 1
Required Tools
Tool Part Number Part Description Qty
A 238-9586 Camshaft Drive Group 1
C 8T-3168 Pilot Assembly 2
4J-7945 Bolt 2
D 8T-3167 Guide Assembly 1
E 8T-3169 Crank Assembly 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01226804
Typical example
The following steps are for the installation of a camshaft in the G3512 Engines and G3516 Engines. The camshaft is in two pieces.
Install Tooling (D) on the flywheel housing. Do not tighten the bolts on Tooling (D).
Install Tooling (C) on the end of the front half of the crankshaft.
Ensure that the camshaft and the camshaft bearings are clean. Place clean engine oil on the lobes and the journals of the camshaft. Also place clean engine oil on the camshaft bearings.
Attach a suitable lifting device to the front half of camshaft (12). The camshaft for G3512 Engines has a weight of approximately 63 kg (139 lb). The camshaft for G3516 Engines has a weight of approximately 82 kg (181 lb). Position the front half of camshaft (12) in the engine until Tooling (C) is in the first camshaft bearing.
Rotate camshaft (12) and tighten the bolts for Tooling (D).
Rotate camshaft (12) and insert camshaft (12) until camshaft (12) is slightly protruding from Tooling (D).
Illustration 2 g00579259
Typical example
Illustration 3 g00579148
Typical example
If the dowel was removed from the front half of camshaft (12), install the dowel. The dowel should be 22.0 0.5 mm (0.87 0.02 inch) from the surface of the camshaft. Note: Ensure that the camshafts are installed according to the marks on the ends of the camshafts.
Attach a suitable lifting device to the rear half of camshaft (13). Install spacer (15) and the rear half of camshaft (13) onto the front half of camshaft (12). Install bolts (14) and tighten to a torque of 55 7 N m (41 5 lb ft).
Install Tooling (C) and Tooling (E) on the end of camshaft (13).
Rotate camshaft (13) and insert the camshaft into the engine.
Remove all Tooling. Repeat Steps 1.a through 1.j for the camshaft on the opposite side of the engine. Go to Step 3.
The following steps are for the installation of a camshaft in the G3508 Engines. The camshaft is in one piece.
Install Tooling (D) on the flywheel housing. Do not tighten the bolts on Tooling (D).
Install Tooling (C) on the ends of the camshaft.
Ensure that the camshaft and the camshaft bearings are clean. Place clean engine oil on the lobes and the journals of the camshaft. Also place clean engine oil on the camshaft bearings. Note: Ensure that the camshafts are installed according to the marks on the ends of the camshafts.
Attach a suitable lifting device to the camshaft. The weight of the camshaft is approximately 42 kg (93 lb). Insert the camshaft in the engine until Tooling (C) is in the first camshaft bearing.
Install Tooling (E). Rotate the camshaft and tighten the bolts on Tooling (D).
Rotate the camshaft and insert the camshaft into the engine.
Repeat Steps 2.a through 2.f for the camshaft on the opposite side of the engine. Go to Step 3.
Illustration 4 g00579144
Install thrust washers (10) and bolts (9) that fasten the camshaft to the engine.
Illustration 5 g00579261
If the camshaft is out of time more than 18 degrees (approximately 1/2 of the timing pin is out of the groove), the valves can make contact with the pistons. This will cause damage to the engine. Refer to Testing and Adjusting, "Camshaft Timing" for more information.
Remove timing pin (16) from the storage position on the side of the engine.
Turn the camshaft until timing pin (16) can be installed through the cylinder block and into groove (17) that is in the camshaft.
Repeat Steps 4 and 5 for the camshaft on the opposite side of the engine.
Illustration 6 g00579262