41805 Mercury SCREW-MERCURY SWITCH AND COVER

Illustration 1 g00892504
Typical example
(1) Cylinder liner Outside diameter of cylinder liner ... 104.25 to 104.28 mm (4.105 to 4.106 inch)Inside diameter of cylinder liner ... 100.00 to 100.03 mm (3.937 to 3.938 inch)Maximum permissible wear of cylinder liner bore ... 0.25 mm (0.010 inch)Interference fit of cylinder liner in cylinder block ... 0.03 to 0.08 mm (0.001 to 0.003 inch)Flange thickness of cylinder liner ... 3.81 to 3.86 mm (0.150 to 0.152 inch)The projection of the liner flange can be 0.10 mm (0.004 inch) above to 0.10 mm (0.004 inch) below the top face of the cylinder block. (2) Plug with baffle plates (if equipped) Orientation of baffle plates to the vertical plane ... +/- 5 degreesDepth of plug from face of cylinder block ... 3 mm (0.12 inch) (3) Cylinder block Diameter of the bore for the cylinder liner ... 104.20 to 104.23 mm (4.103 to 4.104 inch)Depth of the recess for the cylinder liner flange ... 3.81 to 3.91 mm (0.150 to 0.154 inch)Diameter of the recess for the cylinder liner flange ... 107.82 to 107.95 mm (4.245 to 4.250 inch) (4) Tighten the bolts that fasten the housing for the crankshaft rear seal to the cylinder block to the following torque. ... 22 N m (16 lb ft) (5) Tighten the bolts that fasten the housing for the crankshaft rear seal to the bridge to the following torque. M6 ... 13 N m (10 lb ft)M8 ... 22 N m (16 lb ft) (6) Bridge bolt Use the following procedure in order to install the bridge bolts.
Use a straight edge in order to ensure that the bridge is aligned with the front face of the cylinder block.
Evenly tighten the bridge bolts to a torque of 16 N m (12 lb ft).
When the bridge is installed on the cylinder block, apply a thin bead of 8T-9013 Silicone Sealant into the groove at each end of the bridge. (7) Main bearing cap bolts Use the following procedure in order to install the main bearing cap bolts.
Apply clean engine oil to the threads of the main bearing cap bolts.
Put the main bearing caps in the correct position that is indicated by a number on the top of the main bearing cap. Install the main bearing caps with the locating tabs in correct alignment with the recess in the cylinder block.
Evenly tighten the main bearing cap bolts to a torque of 265 N m (195 lb ft). (8) Bore in the cylinder block for the main bearings ... 80.416 to 80.442 mm (3.1660 to 3.1670 inch) (9) Camshaft bearing Inside diameter of the camshaft bearing for the number 1 camshaft journal ... 50.79 to 50.85 mm (2.000 to 2.002 inch)Bore diameter in the cylinder block for the number 1 camshaft bearing ... 55.56 to 55.59 mm (2.187 to 2.189 inch)Bore diameter in the cylinder block for the number 2 camshaft journal ... 50.55 to 50.60 mm (1.990 to 1.992 inch)Bore diameter in the cylinder block for the number 3 camshaft journal ... 50.04 to 50.09 mm (1.970 to 1.972 inch)Total height of cylinder block between the top and the bottom faces. ... 441.12 to 441.33 mm (17.367 to 17.375 inch)Piston Cooling Jets (If Equipped)
Illustration 2 g00631670 (1) Tighten the piston cooling jets to the following torque. ... 27 N m (20 lb ft) (2) Diameter of rod ... 1.70 mm (0.067 inch) (3) Cylinder block Note: Ensure that the piston cooling jet is positioned correctly on the dowel in the cylinder block (not shown).Use the following procedure in order to ensure the correct alignment of the piston cooling jet.
Insert rod (2) into the end of the piston cooling jet. Rod (2) should protrude out of the top of the cylinder block.
Use the following dimensions to locate the center point of diameter (C). Dimension (A) ... 33 mm (1.3 inch)Dimension (B) ... 21 mm (0.8 inch)Diameter (C) ... 14 mm (0.6 inch)Note: Dimension (A) and dimension (B) are tangent to the cylinder bore.
Position rod (2) within diameter (C).