57841 Mercury SCREW, STARTER MOTOR COVER TO CRANKCASE (2 3/4")

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Guide Stud
M8 by 100 mm 4
B 6V-6640 Sealant -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
If necessary, install the plate for the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan Plate - Remove and Install" for the correct procedure.
Illustration 1 g02010373
Illustration 2 g02445176
Install Tooling (A) to Positions (X) in the cylinder block.
Ensure that engine oil pan (11) is clean and free from damage.
Position a new gasket (5) onto engine oil pan (11).
Install new bobbins (13) to the engine oil pan. Do not install the bobbins in Positions (X). Refer to Illustration 1. Note: The bobbins are held captive by the gasket.
Ensure that the gasket surface of the isolating frame is clean and from damage.
Align the assembly of the engine oil pan with Tooling (A). Install the assembly of the engine oil pan to the isolating frame.
Install bolts (12) in Position (Z) to the bobbins finger tight.
Install bolts (14) to the bobbins finger tight.
Illustration 3 g02010374
(X) Position of guide studs.
(Z) Position of short bolts.
Sequence for tightening the bolts
Tighten bolts (12) and bolts (14) to a torque of 22 N m (195 lb in). Tighten the bolts in the sequence that is shown in Illustration 3.
Remove Tooling (A).
Illustration 4 g02010375
Sequence for tightening the bolts
Install the four remaining bolts (12). Tighten the bolts to a torque of 22 N m (195 lb in). Tighten the bolts in the sequence that is shown in Illustration 4.
Illustration 5 g02445177
Illustration 6 g02445276
Install a new O-ring seal (7) to drain plug (6). Install drain plug (6) to engine oil pan (11). Tighten the oil drain plug to a torque of 34 N m (301 lb in).
If necessary, follow Step 14.a through Step 14.c in order to install the assembly of the dipstick tube.
Install a new O-ring seal (3) and new seal (4) to tube assembly (1).
Apply Tooling (B) to the threads of nut (2). Install the tube assembly to the engine oil pan. Note: Ensure that the orientation of the tube assembly is correct.
Tighten nut (2) to a torque of 18 N m (159 lb in).
If necessary, follow Step 15.a through Step 15.c in order to install oil level switch (8) to engine oil pan (11).
Install a new O-ring seal (9) (not shown) to oil level switch (8).
Install oil level switch (8) to engine oil pan (11). Tighten the oil level switch to a torque of 34 N m (301 lb in).
Connect the Original Equipment Manufactures (OEM) wiring harness to wiring harness assembly (10) for oil level switch (8). Install a new cable strap to the wiring harness assembly. Note: Ensure that the cable strap meets the OEM specification.
Fill the engine oil pan to the correct level. Refer to Operation and Maintenance Manual, "Oil Filter Change" for the correct procedure.