809571003 Mercury SCREW

2. Remove wiring harness (3) for glow plugs after removing two bolts (1) and disconnecting wires.3. Remove inner fuel lines (2). 4. Remove drive cable (7) for tachometer from left camshaft housing. Remove oil line from turbocharger and clip that holds oil line for turbocharger to housing from right camshaft housing. Remove clip for fuel lines from right camshaft housing.5. Remove the eleven bolts (6) that hold the camshaft cover to the cylinder head.6. Remove cover (5) after removing seven nuts (4) and one bolt that hold cover to camshaft housing. 7. Remove two bolts (8) and two nuts (9) that hold the camshaft housing to the cylinder head. 8. Install two 3/8"-16NC eyebolts into the housing and remove the camshaft housing with a hoist. Weight is 80 lb. (37 kg).Install Camshaft Housing
1. Turn screws for valve adjustment in the rocker arms to give maximum valve clearance. 2. Put timing marks (1) on camshaft gears in alignment and install the dowel (2) for timing through the housing into the camshaft.3. Turn the crankshaft so the No. 1 piston is at top center for the compression position. See LOCATING TOP CENTER COMPRESSION POSITION FOR THE NO. 1 PISTON in TESTING AND ADJUSTING. Also make a check by installing the timing pin for the fuel injection pump. See FUEL INJECTION PUMP CAMSHAFT TIMING in TESTING AND ADJUSTING.4. Put camshaft housing in position on the cylinder head with a hoist. Make sure gears are engaged correctly. Remove eyebolts. 5. Install two bolts (3) and two nuts (4) that hold camshaft housing to the cylinder head. 6. Install cover (6) with seven nuts (5) and one bolt (9).7. Install the eleven bolts (7) that hold the camshaft cover to the cylinder head.8. Install drive cable (8) for tachometer on left camshaft housing. Install oil line from turbocharger and clip that holds oil line for turbocharger to housing on right camshaft housing. Install clip for fuel lines to right camshaft housing.9. Install inner lines and tighten nuts to a torque of 30 5 lb.ft. (4.1 0.7 mkg). 10. Install wiring harness (11) for glow plugs with two bolts (10) and connect wires.11. Remove all timing pins and install them in their storage areas.12. Make an adjustment for valve clearance to give .008 in. (0.2 mm) for the intake valves and .020 in. (0.5 mm) for the exhaust valves.end by: a) install fuel linesb) install camshaft housing coverDisassemble Camshaft Housing
start by: a) remove camshaft housing 1. Remove the eight bolts (1) that hold the gears (2) to the camshafts and remove the gears. 2. Remove the plate (5) that holds the camshafts in position after removing two bolts (4) that hold plate to housing.3. Remove camshafts (3) by sliding them out of the housing. 4. Remove two bolts (6) that hold shafts for rocker arms in housing. 5. Remove cover (7) after removing the bolts (8) that hold it to the housing.6. Remove tachometer drive and service meter (10) on left housing and cover with hole for the oil line from the turbocharger on the right housing after removing the bolts (9) that hold them to the housings.7. Remove rocker arm shafts from housing with a brass punch and hammer. Remove rocker arms as shaft is removed from housing.Assemble Camshaft Housing
1. Push the shaft (1) for rocker arms into the housing and install the rocker arms (2) on the shaft as it is pushed into the housing.2. Install two bolts that hold the shafts in the housing. 3. Install the cover (4) with the bolts (3) that hold it to the housing.4. Install tachometer drive and service meter (6) on the left housing and the cover with hole for the oil line from the turbocharger on the right housing with the bolts (5) that hold them to the housings. 5. Install the camshafts (7) by sliding them into the housing. The camshaft with the drive flange on the end must be installed to operate the tachometer and service meter.6. Install the plate that holds the camshafts in position with two bolts. 7. Install the dowel (9) for timing through the housing into the camshaft and install the gears (8) with the "V" marks in alignment.8. Install the eight bolts (10) that hold the gears to the camshafts.end by: a) install camshaft housing