816190A 4 Mercury SENDER ASSEMBLY, Oil Level

Table 1
Required Tools
Tool Part Number Part Description Qty
A - Lifting Slings 2
B 8T-5096 Dial Indicator 1
C - Magnetic Base and Stand 1
D 8T-3052 Degree Wheel 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Clean the crankshaft and inspect the crankshaft for wear and damage. Refer to Specifications, "Crankshaft" for more information. If necessary, replace the crankshaft or recondition the crankshaft.
Ensure that parent bores for bearing shells in the cylinder block are clean. Ensure that the threads for the main bearing bolts in the cylinder block are clean and free from damage.
Clean the main bearing shells and the thrust washers. Inspect the main bearing shells and the thrust washers for wear and damage. If necessary, replace the main bearing shells and the thrust washers.Note: If the main bearing shells are replaced, check whether oversize main bearing shells were previously installed. If the thrust washers are replaced, check whether oversize thrust washers were previously installed.
Illustration 1 g06363317
Install upper main bearing shells (5) to the cylinder block. Ensure that the locating tabs for the upper main bearing shells are seated in the slots in the cylinder block.Note: The upper main bearing shells have a groove and two oil holes.
Lubricate upper main bearing shells (5) with clean engine oil.
Illustration 2 g06363301
Attach Tooling (A) and a suitable lifting device to crankshaft (4). Lift crankshaft (4) into the cylinder block. The weight of the crankshaft is approximately 28 kg (62 lb).Note: Do not damage any of the finished surfaces on the crankshaft. Do not damage the main bearing shells.
Remove Tooling (A) after installation of the crankshaft to the cylinder block.
Lubricate thrust washers (6) with clean engine oil. Install thrust washers (6) to No. 3 main bearing in the cylinder block.Note: The grooves in the thrust washers must be located against the crankshaft. The thrust washers have a locating tab at one end. Ensure that the locating tabs are correctly seated in the cylinder block.
Illustration 3 g06363082
Install lower main bearing shells (3) into main bearing caps (2). Ensure that the locating tabs for the lower main bearing shells are correctly seated into the slots in the bearing caps.Note: The lower main bearing shells are plain bearings that do not have oil holes.
Lubricate lower main bearing shells (3) and lubricate the journals of the crankshaft with clean engine oil. Install main bearing caps (2) to the cylinder block.Note: Ensure the correct location and orientation of main bearing caps (2). The locating tabs for the upper and the lower main bearing shells should be on the same side of the engine.
Illustration 4 g06363079
Lubricate the threads of bolts (1) with clean engine oil. Lubricate the underside of the heads of bolts (1) with clean engine oil.
Illustration 5 g06363120
Install bolts (1) to main bearing cap (2). Evenly tighten the bolts to pull cap (2) into position using the numerical sequence. Refer to illustration 5. Ensure that the cap is correctly seated.Note: Do not tap the main bearing cap into position as the bearing shell may be dislodged.
Tighten bolts (1) to a torque of 80 N m (59 lb ft) in the numerical sequence. Refer to illustration 5.
Rotate the crankshaft to ensure that there is no binding.
Use tooling (D) and turn the bolts through an additional 90 degrees in the numerical sequence shown in Illustration 5.
Illustration 6 g06363155
Check the crankshaft end play. Push the crankshaft toward the front of the engine. Install Tooling (B) and Tooling (C) to the cylinder block and the rear face of the crankshaft. Push the crankshaft toward the rear of the engine. Use Tooling (B) to measure the crankshaft end play. The permissible crankshaft end play is 0.10 mm (0.004 inch) to 0.41 mm (0.016 inch).
Install the connecting rod bearings. Refer to Disassembly and Assembly, "Connecting Rod Bearings - Install" for the correct procedure.End By:
Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install" for the correct procedure.
Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install" for the correct procedure.
Install the crankshaft rear-end oil seal. Refer to Disassembly and Assembly, "Engine Crankshaft Rear Seal - Remove and Install" for the correct procedure.
Install the crankshaft front-end oil seal. Refer to Disassembly and Assembly, "Engine Crankshaft Front Seal - Remove and Install" for the correct procedure.
Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install" for the correct procedure.