803509 4 Mercury SCREW ASSEMBLY, Pilot

Table 1
Required Tools
Tool Part Number Part Description Qty
A 8T-3052 Degree Wheel 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Discard all used Connecting Rod fasteners.
Inspect the pins of the crankshaft for damage. If the crankshaft is damaged, replace the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Remove" and Disassembly and Assembly, "Crankshaft - Install" for the correct procedure. Ensure that the main bearing shells are clean and free from wear and damage. If necessary, replace the main bearing shells. Note: If the main bearing shells are replaced, check whether oversize main bearing shells were previously installed.
Ensure that the crankshaft is in the bottom center position.
Illustration 1 g02015553
Install upper bearing shell (4) into connecting rod (5). Ensure that the locating tab for the upper bearing shell is correctly seated in the slot in the connecting rod. Note: The ends of the upper bearing shell must be centered in the connecting rod. The ends of the upper bearing shell must be equally positioned in relation to the mating faces of the connecting rod.
Lubricate upper bearing shell (4) with clean engine oil.
Carefully guide connecting rod (5) against the crankshaft pin. Note: Do not allow the connecting rod to contact the piston cooling jet.
Clean connecting rod cap (2). Install lower bearing shell (3) into connecting rod cap (2). Ensure that the locating tab for the lower bearing shell is correctly seated in the slot in the connecting rod cap.
Lubricate the pin of the crankshaft and lubricate lower bearing shell (3) with clean engine oil.
Illustration 2 g03005637
Install connecting rod cap (2) to connecting rod (5). Note: Ensure that etched number in Position (X) on connecting rod cap (2) matches etched number in Position (X) on connecting rod (5). Ensure the correct orientation of the connecting rod cap. The locating tab for the upper bearing shell and the lower bearing shell should be on the same side.Note: Do not reuse the old bolts in order to secure the connecting rod cap.
Install new bolts (1) and tighten to 50 N m (36 lb ft). Turn the bolts an additional 70 degrees in a clockwise direction. Use Tooling (A) in order to achieve the required torque.
Ensure that the installed connecting rod assembly has tactile side play. Rotate the crankshaft in order to ensure that there is no binding. Note: If all connecting rod bearings require replacement, the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairs of cylinders. 1 and 4 then 2 and 3. Ensure that the installation procedure on one pair connecting rods is completed before starting the removal procedure on the next pair of connecting rods.
Repeat Step 1 through Step 10 in order to install the remaining connecting rod bearings. End By:
If necessary, install the balancer. Refer to Disassembly and Assembly, "Balancer Install" for the correct procedure.
Install the engine oil suction pipe. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install" for the correct procedure.